Re-pulpable insulated paper products and methods of making and using the same

ABSTRACT

Insulated paper products are disclosed. Methods of making and using insulated paper products are also disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims the benefit of priority to U.S.Provisional Patent Application Ser. No. 62/739,735 filed on Oct. 1, 2018and entitled “RE-PULPABLE INSULATED PAPER PRODUCTS AND AND METHODS OFMAKING AND USING THE SAME,” the subject matter of which is herebyincorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to insulated paper products. Thepresent invention further relates to methods of making and usinginsulated paper products.

BACKGROUND OF THE INVENTION

With the advent of on-line shopping, many goods are now delivereddirectly to the consumer's front door from distributors such as Amazonand others. Food and other temperature sensitive materials are typicallyshipped inside an insulated box. The insulation is typically some kindof polymeric closed-cell foam or a poly(ethylene) bubble-wrap typematerial and perhaps a metalized reflective film, which is inserted intothe cardboard box prior to shipping.

While cheap to produce, manufacture, and highly insulating, expandedpolystyrene has many disadvantages. Expanded polystyrene (1) ispersistent in the environment, contributing to ocean pollution and longterm landfills, (2) is frequently litter that is unsightly and may causeobstruction in the guts of smaller animals when ingested, (3) is notrecyclable in most municipalities, (4) has to be separated from the boxprior to recycling, (5) has to be inserted inside the box, and (6) doesnot nest, meaning that it is expensive to ship, and bulky to store.

The economic impact of using incompatible materials in a productionenvironment is often underappreciated. FIG. 42 shows how a stack offreshly made corrugated cardboard sheets are cut into an unfolded box bya rotary die/roller, ready to be inspected by quality control andshipped off to the customer. Card cuttings and trimmings from thisprocess, along with any reject box, are shredded and then fed directlyback into the repulping process (FIG. 7) as pre-consumer scrap card.This is made back into furnish. Introducing treatments, coatings,liners, and other materials into the cardboard box that cannot be feddirectly back into the re-pulping process complicates the productionprocess and risks increasing paper machine (FIG. 8) down-time ifmistakes are made. Using an incompatible material means that the scrap,and any trimmings from that cardboard material must be segregated, andhandled separately from the usual cardboard.

Presently, frozen or chilled food is shipped in cardboard containerswith thermally insulating inserts. Such inserts are either expandedpoly(styrene) foam (sold under the tradename Styrofoam), and orpoly(olefin) bubble wrap which may or may not be metalized to decreaseradiative heat transfer. Occasionally, expanded polyurethane foam isused in combination with a plastic film liner. None of these materialscan be used in a cardboard box manufacturing line because any scrapcontaining these synthetic polymers would have to be segregated from theregular pulp. For this reason, cardboard boxes are made separately fromthe insulating material. Furthermore, the insulating material has to beremoved prior to recycling the box as many municipalities do not recycleplastic films or expanded polystyrene.

For similar reasons, some paper beverage cups are also difficult torecycle. They are coated with a low molecular weight polyethylene, whichcauses problems when introduced into the pulp.

What is needed is a highly thermally insulating paper structure thatprovides one or more of the following benefits: (1) is non-toxic andsafe for use with food, (2) maintains frozen or chilled foodtemperatures for the time needed to ship foods, (3) is curb-sideready—that is recyclable by municipal recycling services withoutseparation or segregation from other papers in the waste stream, (4)trimmings generated during the paper product (e.g., cardboard box)manufacture are able to be repulped and directly sent back into thepaper product (e.g., cardboard box) production stream without having tobe segregated, (5) is able to withstand crushing by stacking, (6) isable to maintain integrity with condensation formation after beingplaced in a freezer then exposed to humid air, and (7) is biodegradableor biodestructable.

SUMMARY OF THE INVENTION

The present invention is directed to insulated paper products that (1)insulate food positioned therein and/or surrounded thereby, (2) arebiodegradable or biodestructable, recycleable, repulpable, and (3) donot require additional inserts to keep food cold or hot. The disclosedinsulated paper products utilize multiple ways to introduce insulatingmaterials into and/or onto a variety of paper products. For example,thermally insulating materials may be introduced into the paper furnishprior to casting the furnish onto a paper-forming wire mesh.Alternatively, or in addition, the insulating material may be introducedbetween layers of paper as they are formed. Alternatively, or inaddition, insulating materials may be incorporated into adhesives usedto bond paper layers to one another. Still further, insulating materialsmay be included within a coating, which is then coated onto a variety ofpaper products.

The present invention is directed to insulated paper products. In oneexemplary embodiment, the insulated paper product of the presentinvention comprises an insulated paper product comprising one or morepaper layers and insulating material, wherein (I) when two or more paperlayers are present, the two or more paper layers form an integral paperproduct, and (2)(a) at least one of (i) one layer in combination withthe one or more paper layers comprises the insulating material, and (ii)one paper layer within the one or more paper layers may have anon-uniform distribution of insulating material therein, or (2)(b) theintegral paper product itself has a non-uniform distribution ofinsulating material therethrough.

In another exemplary embodiment, the insulated paper product of thepresent invention comprises a corrugated integral paper productcomprising: a first linerboard layer comprising one or more first paperlayers, a second linerboard layer comprising one or more second paperlayers, and a fluted paper layer comprising one or more fluted paperlayers or a honeycomb layer positioned between the first linerboardlayer and the second linerboard layer, wherein (i) the first linerboardlayer, (ii) the second linerboard layer, and (iii) the fluted paperlayer or the honeycomb layer may each independently comprise insulatingmaterial that has a low thermal conductivity and/or low emissivity.

In another exemplary embodiment, the insulated paper product of thepresent invention comprises a corrugated integral paper productcomprising: a first linerboard layer comprising one or more first paperlayers, a second linerboard layer comprising one or more second paperlayers, and a fluted paper layer comprising one or more fluted paperlayers or a honeycomb layer positioned between the first linerboardlayer and the second linerboard layer, wherein (i) the first linerboardlayer, (ii) the second linerboard layer, and (iii) the fluted paperlayer or the honeycomb layer may each independently comprise insulatingmaterial therein or thereon.

In one desired embodiment, the insulated paper product comprises a fullyrecyclable, re-pulpable, biodegradeable, biodestructable, and thermallyinsulated cardboard box.

The present invention is further directed to methods of making insulatedpaper products. In one exemplary embodiment, the method of making aninsulated paper product comprises: forming an insulated paper productcomprising: one or more paper layers and insulating material, wherein(1) when two or more paper layers are present, the two or more paperlayers form an integral paper product, and (2)(a) at least one of: (i)one layer in combination with the one or more paper layers comprises theinsulating material and (ii) one paper layer within the one or morepaper layers has a non-uniform distribution of insulating materialtherein, or (2)(b) the integral paper product itself has a non-uniformdistribution of insulating material therethrough.

The present invention is further directed to methods for makinginsulated paper products in the form of corrugated structures, andsubsequently forming them into containers. Similar structures may beformed in high volume using a die cutter to make a stack of similar boxnets, or the net for each box may be custom cut using for instance, alaser, or a robot, or an automated abrasive jet, or some other means torapidly produce custom-sized boxes upon demand.

The present invention is even further directed to methods of usinginsulated paper products. In one exemplary embodiment, the method ofusing an insulated paper product comprises: insulating an object (e.g.,food, medicine, pharmaceuticals, ice, flowers, etc.) via any one of theherein-described insulated paper products.

These and other features and advantages of the present invention willbecome apparent after a review of the following detailed description ofthe disclosed embodiments and the appended claims.

BRIEF DESCRIPTION OF THE FIGURES

The present invention is further described with reference to theappended figure, wherein:

FIG. 1 depicts a perspective view of an exemplary paper product of thepresent invention;

FIGS. 2A-2C depict exemplary cross-sectional views of the exemplarypaper product shown in FIG. 1 as viewed along line 2-2 shown in FIG. 1;

FIG. 3 depicts a perspective view of another exemplary paper product ofthe present invention;

FIGS. 4A-4F depict exemplary cross-sectional views of the exemplarypaper product shown in FIG. 3 as viewed along line 4-4 shown in FIG. 3;

FIG. 5 depicts a perspective view of another exemplary paper product ofthe present invention (also referred to herein as “an integral paperproduct”);

FIGS. 6A-6D depict exemplary cross-sectional views of the exemplarypaper product shown in FIG. 5 as viewed along line 6-6 shown in FIG. 5;

FIG. 7 depicts a schematic view of process steps and process componentsused to form the exemplary paper products of the present invention;

FIGS. 8A-8C depict an exemplary process flow in an exemplary papermakingprocess suitable for use in forming the exemplary paper products of thepresent invention;

FIG. 9 depicts a side view of a paper layer forming process stepsuitable for thrilling a single paper layer within any of the exemplarypaper products of the present invention;

FIG. 10 depicts a side view of another paper product forming processstep suitable for forming an exemplary three-layered paper products ofthe present invention;

FIG. 11 depicts a side view of another paper product forming processstep suitable for forming an exemplary paper product of the presentinvention;

FIG. 12 depicts a side view of another paper product forming processstep suitable for forming an exemplary paper product of the presentinvention comprising a layer of insulating material;

FIGS. 13A-13G depict side views of seven paper layer forming processes,each of which is suitable for forming a paper within any of theexemplary paper products of the present invention;

FIG. 14 depicts a perspective view of a paper layer forming process stepsuitable for forming cross-directional flutes within an exemplary paperproduct of the present invention;

FIG. 15 depicts an exemplary cross-sectional view of the exemplaryflute-forming rollers used in the process step shown in FIG. 14 asviewed along line 15-15 shown in FIG. 14;

FIG. 16 depicts a perspective view of a paper layer forming process stepsuitable for forming machine-directional flutes within an exemplarypaper product of the present invention;

FIG. 17 depicts an exemplary close-up view of the exemplaryflute-forming rollers used in the process step shown in FIG. 16 asviewed along the machine direction (MD);

FIGS. 18A-18B depict side views of two exemplary corrugated paperproducts of the present invention;

FIGS. 19A-19C depict exemplary storage containers comprising any one ofthe exemplary insulated paper products of the present invention;

FIG. 19D depicts an exemplary cross-sectional view of the wall structureof the exemplary hot beverage cup shown in FIG. 19C;

FIGS. 20-23A depict additional exemplary storage containers comprisingany one of the exemplary insulated paper products of the presentinvention;

FIG. 23B depicts a close-up cross-sectional view of the wall structureof the exemplary shipping container shown in FIG. 23A;

FIG. 24 depicts an exemplary cross-sectional view of a wall structure ofan exemplary shipping container;

FIGS. 25A-25B depict a paper layer having an uniform distribution ofinsulating particles and a paper layer having a non-uniform distributionof insulating particles;

FIGS. 26A-26B depict possible heat pathways through (i) the paper layerhaving an uniform distribution of insulating particles shown in FIG. 25Aand (ii) and the paper layer having a non-uniform distribution ofinsulating particles shown in FIG. 25B;

FIG. 27 graphically shows the insulating properties of variouspolystyrene cups and paper cup samples containing perlite;

FIG. 28 graphically shows that paper samples with 10% perlite had themost insulating properties relative to paper samples made with any ofthe other materials tested;

FIG. 29 graphically shows that paper samples with 20% perlite had themost insulating properties relative to paper samples made with any ofall the other materials except the activated carbon, which performedslightly better than the perlite-containing paper samples;

FIG. 30 graphically shows that the paper samples with 25% perlite hadthe most insulating properties relative to paper samples made with anyof all the other materials except for paper samples with activatedcarbon, which again performed on par with the perlite-containing papersamples;

FIG. 31 graphically shows that the polystyrene cups were the mosteffective insulators out of all the other non-additive materials;

FIG. 32 graphically shows the change in the rate of heat transfer withthe addition of perlite with a medium/small grade;

FIG. 33 graphically shows how the effective heat transfer rate changeswith an increase in weight percentage of each grade of perlite;

FIGS. 34-35 depict views of an apparatus that may be used to determinethe rate of heat transfer of paper samples and/or insulating materialswith FIG. 34 depicting a cross sectional view of the apparatus and FIG.35 depicting an exploded cross sectional view of the apparatus;

FIG. 36 graphically shows the heat transfer rates of various materials;

FIGS. 37-39 depict views of another apparatus that may be used todetermine the relative emissivity of paper samples and/or insulatingmaterials;

FIG. 40 depicts a view of another apparatus that may be used todetermine the relative emissivity of paper samples and/or insulatingmaterials;

FIG. 41 depicts a view of an apparatus that may be used to form a papersheet;

FIG. 42 depicts a schematic view of known processes for forming boxesfrom a rectangular corrugated sheet with waste (e.g., trimmings anddefective boxes) generated from the process;

FIGS. 43A and 43B depict views of an apparatus that may be used todetermine the rate of heat transfer of paper samples and/or insulatingmaterials with FIG. 43A depicting a cut-away view of modifications to anexpanded polystyrene cooler including dimensions, as well as positioningof the window through the cooler wall, and FIG. 43B depicting a crosssectional view of the test apparatus;

FIG. 44 depicts a photograph of regular bleached secondary fiber pulp(left jar), allowed to settle compared to the floating paper pulp afterit has been combined with surface modified aerogel (right jar);

FIG. 45 shows scanning electron micrographs of paper surfaces containinginsulating additives, comparing the wire side of the resultant paper tothe felt side of the paper for four different materials;

FIG. 46 depicts a bar chart showing the thickness adjusted delta-Ttemperature difference (TART) for various insulating material filledpaper compositions;

FIG. 47 depicts SEMs of surfaces and cross sections of prepared paperscontaining insulating fillers for comparison;

FIG. 48 depicts a corrugated structure of the present invention with oneside coated; and

FIG. 49 depicts single faced corrugate paper hot beverage cup sleevesincluding the net and cross section.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to insulated paper products comprisingfibers 11 (e.g., wood pulp fibers 11) and insulating material 12.Although shown in all figures, each paper layer 10 comprises fibers 11(e.g., wood pulp fibers 11) with or without other paper layer additivesincluding, but not limited to, the insulating material 12. Somedefinitions of fibers, paper, and packaging, as well as productspecification and fiber sources, are provided below.

As used herein, the term “paper” is used to identify a type of non-wovenmaterial in which fibers are randomly oriented in all directions. Fibersprincipally made from cellulose are poured as a slurry on a mesh screen.As the paper is formed, the fibers come into contact with each other,and physically bond with neighboring fibers via a variety ofinteractions, including hydrogen bonding. The fibers originally comefrom plants including trees, although synthetic and mineral fibers, orother types of fibers, may optionally be included. Often, the paper alsocontains recycled fiber. Wood may be sourced from direct harvesting oftrees from forest land, or from lumber industry byproducts (such assawdust).

Paper fibers may include the fibrous portions from many parts, includingsoftwoods (such as those plants with needles instead of leaves, forexample, loblolly pine) and hardwoods. Other plants that yield usefulpaper fibers include but are not limited to bamboo, sugar cane, wheatstraw, reed grass, mischanthus grass, coconut fiber, hemp fiber, cottonfiber, jute, palm, reeds, and papyrus. Cellulose fibers in many plantsare bound together with lignin.

In the case of virgin (non-recycled) fiber, much of the lignin isremoved during the pulping process. Recycled paper may include fibersfrom corrugated, fiber board, writing paper, pressboard, card,newspaper, tissue paper, specialty papers, linerboard, containerboard,boxboard, PE-lined paperboard, carton material, cup stock, or foodboard.

When made from trees, the pulping process involves methods to separatethe individual cellulosic fibers into a slurry, as well as remove someor all of the lignin. Pulping methods may include a) thermomechanicalpulping, which involves the use of steam and sheer forces generatedbetween a spinning and a stationary plate, b) chemical pulping, whichuses strong chemicals to break down the pulp by dissolving the lignin,and/or c) the semi-chem process, which uses a combination of mechanicaland chemical methods. Most often, fluted medium hoard (e.g., flutedmedium board 23) is made using semi-chem process pulp and/or recycledpaper fiber. Other types of pulp include solid bleached sulfate pulp,chipboard, and kraft.

Paper (and paper layer 10), as used herein, may broadly include anymaterial that includes 15% or more cellulose fibers (discussed furtherbelow). Other additives, including insulating material 12, otherparticles/additives/components that impart grease resistant and/or waterresistant, as well as other particles/additives/components to impartstrength. Non-paper (and non-paper layer 30) is anything containing lessthan 15% of cellulose fibers (discussed further below).

As used herein, the term insulating material, such as insulatingmaterial 12, is used to describe inorganic or organic materials thatprovide some degree of insulation. The term insulating material, as ininsulating material 12, does not include air alone or any other gasalone, although air and/or another gas could be trapped within one ormore inorganic or organic insulating material 12.

Paper products 10/100′/60, comprising fibers 11 (e.g., wood pulp fibers11) and insulating material 12, can either be made flat (e.g., insulatedpaper products 100/100′) using a screen to make flat materials, oralternatively be molded, vacuum formed, or thermoformed from a pulpsuspension to form essentially three-dimensional (non-flat) objects(e.g., molded or otherwise formed containers 60 shown in FIGS. 19A-23B).Such three-dimensional paper products include certain packaging, forinstance, egg crates and egg cartons, packaging that protects thecorners of products shipped in the mail, biodegradable compostcontainers, biodegradable plant pots, disposable urinals and bed pansused in hospitals, disposable cat little boxes, and the like. Additives,including insulating material 12, may be included within the paperproducts 10/100′/60 to impart thermal insulation properties, strengthunder moist or wet conditions, impart water repellency or waterproofing, impart grease absorption resistance, increase strength,improve the color, improve printability, or other aesthetic aspects.

When forming a given paper layer 10, dried pulp sheets may be fragmentedusing a hammermill and the fibers 11 dispersed in air. This is oftencalled fluff pulp. The solid-in-air suspension may then be vacuum formedinto products 10/100′/60. Such products include air-laid pads, absorbentmaterials for use in other products such as diapers and feminine hygieneproducts, disposable pet waste pads, or fluff thermal insulation.

Additives, including insulating material 12, may be added to the paperpulp prior to casting on the paper wire or otherwise molding the pulpinto a product 10/100′/60. Alternatively, additives, includinginsulating material 12, may be added at the size press, or after thesteam can dryers. Additives, including insulating material 12, can alsobe added to a clay coating (e.g., coating 30) often applied to linerboard (e.g., liner board 21/22) to make clay coated kraftback, or claycoated newsback.

Paper packaging (e.g., containers 60 shown in FIGS. 19A-23B), formedfrom the insulated paper products 100/100′/100″ of the presentinvention, may include a wide variety of formats, including: regularslotted container (RSC), overlap slotted container, full overlap slottedcontainer, special center slotted container, Bag-in-Box, center specialoverlap slotted container, center special full-overlap slottedcontainer, snap- or 1-2-3-bottom box with tuck top, snap- or1-2-3-bottom box with RSC top, Full Bottom File Box, Hamper Style, Ft.Wayne Bottom or Anderson Lock Bottom, Bellows Style top and BottomContainer, Integral Divider Container, RSC with Internal Divider or SelfDivider Box, Full-telescope Design-style Box, Full-telescopeHalf-slotted Box, Partial-Telescope Design-style Box, Partial-telescopehalf-slotted box, Design-Style Box with cover, Half-slotted Box withcover, Octagonal Double Cover Container, Double cover box, InterlockingDouble-Cover box, double-thickness score-line box, one-piece folder,two-piece folder, three-piece folder, fiver panel folder, one piecefolder with air cell/end buffers (used to protect e.g. books),wrap-around blank, tuck folder, one piece telescope, double-slide box,number 2 or 3 bliss box, recessed end box, self-erecting box, pre-gluedauto bottom with RSC top flaps, four corner tray, self-erectingsix-corner tray, flange box, Arthur lock bottom, valentine lockcontainer, reverse valentine lock container.

Medium board used in the insulated paper products 100/100′/100″ of thepresent invention may be fluted with flutes of different dimensions.See, for example, exemplary fluted medium board 23 shown in FIGS.6A-6D). The Fiber Box Handbook defines flutes and flute dimensions as:A, B, C, E, F, G, K, N, as well as R/S/T/D. The liner and medium papersmay also be tested and rated by different burst grade: 125-350 SW, 23-55ECT, 200-600 DW, 42-82 ECT DW, 700-1300 TW, 67-112 ECT TW. The carton orbox (e.g., box 61) may then be folded into the following industry knownstyles: reverse tuck, snap lock, automatic bottom, straight tuck, tucktop snaplock bottom, tuck top automatic bottom, seal end, beers, mailingenvelopes, folder, and simplex.

As discussed herein, the insulated paper products of the presentinvention may comprise a single paper layer with insulating materialdispersed therein or thereon, or may comprise two or more paper layersin combination with insulating material, wherein the insulating materialis within one or more of the paper layers of the insulated paper productand/or is present as a component within the insulated paper product(e.g., as a separate layer from the paper layers and/or as a fillerwithin a layer or component of the insulated paper product). See, forexample, exemplary insulated paper products 100/100′/100″ in FIGS. 1-6D.

The insulated paper products of the present invention may furthercomprise one or additional layers other than the one or more paperlayers and possible layers of insulating material. Suitable additionallayers may include, but are not limited to, a coating that providesenhanced emissivity of the insulated paper product, a coating thatprovides a desired color and/or surface texture for the insulated paperproduct, and a coating that provide enhanced water-repellency (e.g.,waterproofing properties) to the insulated paper product. See, forexample, exemplary insulated paper products 100/100′/100″ in FIGS.6A-6D.

In exemplary insulated paper product 100/100′/100″ shown in FIG. 6A, acorrugated cardboard structure 100/100′/100″ comprises two liner boards21/22 bonded to a fluted medium board 23. One (or both) of the linerboards 21/22 may be coated (e.g., clay coated) with coating layer 30 foraesthetics. The fluted medium 23 may have a range of flute dimensions,which are classified by the industry as A-flute through F-Flute. Eachliner board 21/22 may be made from one ply of paper 10/100′, or it maycomprise two or more plies 10/100′. Other types of board that could beused in combination with the above-described insulated paper products100/100′/100″ discussed above: pressboard—pressed fiber board; honeycombboard—e.g., two liner boards 21/22 with a honeycomb spacer in between.

In exemplary insulated paper product 100/100′/100″ shown in FIG. 6B, acorrugated cardboard structure 100/100′/100″ comprises two liner boards21/22 bonded to a fluted medium board 23, and demonstrates severalopportunities for incorporation of insulating additives 12 into thestructure of corrugated cardboard 100/100′/100″. First, insulatingadditives 12 have been added to the furnish of the fluted medium 23.Second, the flutes have been further isolated from heat transfer viaconduction by incorporating insulating additives 12 into the starchadhesive 40 that bonds each flute (e.g., of fluted medium 23) to theliner boards 21/22. Third, the liner board 21 is coated with insulatingadditives 12 via a coating 30. Fourth, to slow radiative heat transfer,a low emissivity coating 30 is overcoated on the outside of thecorrugated cardboard structure 100/100′/100″ (e.g., a box 61). Such acoating 30 will reflect vs. absorb radiative heat and infra-redradiation.

In exemplary insulated paper product 100/100′/100″ shown in FIG. 6C,another corrugated cardboard structure 100/100′/100″ comprises two linerboards 21/22 bonded to a fluted medium board 23, and again demonstratesseveral opportunities for incorporation of insulating additives 12 intothe corrugated cardboard structure 100/100′/100″. First, insulatingadditives 12 have been added to the furnish of the fluted medium board23, however, in such a way that the insulating material 12 haspreferentially segregated to one face (e.g., the upper face as shown) ofthe medium fluted board 23 over the other (e.g., the lower face asshown). Second, the flutes (of the medium fluted board 23) have beenfurther isolated from heat transfer via conduction by incorporatinginsulating additives 12 into the starch adhesive 40 that bonds eachflute of the medium fluted board 23 to the liner boards 21/22. Third,another coating 310 containing insulating additives 12 has beenincorporated in the valleys 231 of the flutes. Fourth, one of the linerboards 21/22 contains insulating additives 12 distributed in anon-uniform manner (e.g., such as in first liner board 21 as shown).Fifth, to slow radiative heat transfer, a low emissivity coating 30 isovercoated on the outside faces of both liner boards 21/22. Such acoating 30 will reflect vs. absorb radiative heat and infra-redradiation.

In exemplary insulated paper product 100/100′/100″ shown in FIG. 6D,another corrugated cardboard structure 100/100′/100″ comprises two linerboards 21/22 bonded to a fluted medium board 23, and again demonstratesseveral opportunities for incorporation of insulating additives 12 intothe insulated paper product 100/100′/100″. First, insulating additives12 have been added to the furnish of the fluted medium board 23 in sucha way that the insulating materials 12 are distributed evenly throughoutthe thickness of the one or more paper layers 10/100′. Second, theflutes of the fluted medium board 23 have been further isolated fromheat transfer via conduction by incorporating insulating additives 12into the starch adhesive 40 that bonds each flute of the fluted mediumboard 23 to the liner boards 21/22. Third, another coating 30 containinginsulating additives 12 has been coated onto one of the liner board 21.Fourth, the second liner board 22 contains insulating additives 12distributed in a non-uniform manner. Fifth, to slow radiative heattransfer, a low emissivity coating 30 is overcoated on the outside facesof one of the liner boards 21. Such a coating 30 will reflect vs. absorbradiative heat and infra-red radiation.

In addition, any of the insulated paper products of the presentinvention described herein may be configured into a variety of shapes.For example, in some embodiments, the insulated paper product is in theform of an insulated cup or mug that may be used to house a hot beveragesuch as coffee. Such insulated paper products may be used instead ofSTYROFOAM® cups, eliminating the disposal and environmental problemsassociated with STYROFOAM® cups. In other embodiments, the insulatedpaper product is in the form of insulated packaging for temporarystorage and transport of items such as food, medicines, dc. Suchinsulated paper products may be in the form of an insulated box,corrugated or not corrugated, as well as many other packaging itemsdiscussed herein. See, for example, exemplary insulated paper products100/100′/100″ in FIGS. 19A-23B.

Regardless of configuration and/or shape, the insulated paper products100/100′/100″ of the present invention provide a degree of insulationdue to the construction of one or more paper layers 10 within a giveninsulated paper products 100/100′/100″. For example, FIGS. 25A-25Bdepict cross-sectional representations of exemplary paper compositelayers 10 containing insulating material particles 12, represented ascircles, and fibers 11. Both paper composite layers 10 contain the samenumber of circles, representing the insulating material particles 12.The paper composite layer 10 shown in FIG. 25A has a substantiallyuniform distribution of insulating material particles 12, whereas thepaper composite layer 10 shown in FIG. 25B has a non-uniformdistribution of insulating material particles 12.

In addition, FIGS. 26A-26B provide a representation of possibleconductive pathways that heat could take through exemplary papercomposite layers 10 shown in FIGS. 25A-25B. While the invention shouldnot be limited by theory, in the case of the paper composite layer 10shown in FIG. 25A, it is believed that the insulating particles 12,evenly distributed, lengthen the pathway of the conducted heat, therebyslowing heat transfer down. While the paper composite layer 10 shown inFIG. 258 has the same number of particles 12 (represented by the samenumber of circles), the particles 12 are concentrated in a narrow layerof the paper composite layer 10. Heat is partially blocked by the highconcentration of insulating particles 12, reducing heat flowconsiderably in the paper composite layer 10 shown in FIG. 258 comparedto the paper composite layer 10 shown in FIG. 25A.

The present invention is further directed to methods of making and usingthe herein-disclosed and described insulated paper products. Theinsulated paper products may be made using papermaking equipment andtechniques so as to produce one or more paper layers. As discussedherein, the methods of making the insulated paper products of thepresent invention involve the strategic placement of one or moreinsulating materials within a given insulated paper product and/or thestrategic placement of one or more optional coatings on the insulatedpaper product so as to provide superior insulating properties, as wellas other properties to the insulated paper product. Exemplary methodsteps and procedures for forming insulated paper products of the presentinvention are shown/described in FIGS. 7-17.

FIG. 7 describes an exemplary method 200 for forming paper from woodpulp and pre-consumer trimmings/scrap cardboard. After removal of barkand leaves etc., a wood composition of tree-wood is approximately ⅓cellulose, ⅓ lignin, and ⅓ water. Wood is fed into a disintegrator 201,which grinds the wood and feeds it into a beater 202. Pulp is made inthe beater 202. After prolonged beating, the fibers undergomorphological changes Fibers tend to collapse from round fibers intomore of a kidney shaped cross-section, and the fibers become slightlymore hydrophobic as beating continues.

As the layers of paper are formed and further processed, trimmings andrejected card (e.g., damaged, warped, etc.) is shredded and fed backinto the pulping process. The card is washed in a wash clean device 203to the extent possible to remove inks etc., then fed back into thebeater 202.

FIGS. 8A-8C depict an exemplary process of forming paper sheets 10. Asshown in FIG. 8A, pulp (furnish) is pumped into a header box 204. Thefiber content of the furnish is approximately 1-2 wt % at this stage. Agate 205 allows furnish to flow out onto the moving forming wire (a finemesh conveyor) 206. The forming wire 206 may be 75-100 feet long.Initially, water drains via gravity, however, further down, vacuum boxes207 beneath the wire 206 assist water removal, increasing the fibercontent to around 20-30 wt %.

As shown in FIG. 8B, the material (˜20-30 wt % fiber) is then fedthrough one or more felt presses 208, which “blot” the precursor paper(i.e., precursor to paper layer 10), removing more water, and increasingthe fiber content to around 45-50 wt %. If starch or another additive isto be applied, then that may be done at the size press 209 prior todrying.

As shown in FIG. 8C, drying may be affected in a number of ways,including running over steam cans 210, or entering a long hot air dryingtunnel (not shown). After passing through calendar rolls 211 and priorto winding, the paper 10 may be between 6 to 10% moisture content.

FIG. 9 depicts an exemplary furnish flowing out of a header box gate 205onto the moving forming wire (a fine mesh conveyor) 206, showing waterdraining through the moving forming wire 206, and fibers coalescing andconcentrating as the wire 206 moves along.

FIG. 10 depicts an exemplary process step for forming a multiple plylinerboard 100. The linerboard 100 may be made from more than one paperply 10 during the manufacturing process. More than one header box 204and wire line 206 may be running simultaneously, so that two or more wetpaper sheets 10 are combined at laminator nip rolls 212 prior toentering the felt press 208. FIG. 10 shows three plies 10 being combinedto make a thicker linerboard 100 prior to entering a felt press 208.

FIG. 11 depicts details of an exemplary linerboard 100 suitable for usein forming an insulated paper product 100/100′/100″ of the presentinvention or a component (e.g., a layer or outer linerboard) of aninsulated paper product 100/100′/100″ of the present invention. As shownin FIG. 11, exemplary linerboard 100 comprises two sheets of paper 10laminated to one another. Exemplary linerboard 100 further comprises afirst clay coating 30 directly on an outer surface 13 of one of thepaper layers 10, and an outermost second white clay coating 30 so as toprovide a printable surface/layer 38 for exemplary linerboard 100. Firstclay coating 30 evens out the valleys and troughs of the rough paper 10,leaving a smooth surface for high-quality printing.

FIG. 12 depicts details of another exemplary linerboard 100 suitable foruse in forming an insulated paper product 100/100′ of the presentinvention or a component (e.g., a layer or outer linerboard) of aninsulated paper product 100/100′ of the present invention. As shown inFIG. 12, a thermally insulating additive layer 20 comprising insulatingmaterial 12 may be incorporated into an exemplary linerboard 100 via anadditive applicator 213. In this case, layer 20 of insulating material12 is positioned between two layers of paper 10 within exemplarylinerboard 100 comprising three layers of paper 10. As shown in FIG. 12,a second additive applicator 213 could be used to provide another layerof additives (e.g., insulating material 12 or some other material)between the other two layers of paper 10 within exemplary linerboard 100comprising three layers of paper 10.

FIGS. 13A-13G depict various ways of incorporating insulating material12 within or on a given paper layer 10 or an insulated paper product100/100′. As shown in FIG. 13A, thermally insulating material 12 isadded to the pulp, wherein the thermally insulating material 12 has adensity that that is close to that of water. In this case, as thefurnish drains, the insulating materials 12 are incorporated evenly,substantially uniformly throughout the paper 10 thickness.

In FIG. 13B, a non-uniform distribution of insulating material 12results from the use of insulating material 12 having a density lower(or much lower) than that of water. In this case, gravitational forcescause water to drain downward, but insulating material 12 tends to moveupward as the furnish proceeds along moving wire 206. This leads to ahigher concentration of insulating particles 12 on an upper side/surfaceof the paper 10. In some embodiments of the present invention, it hasbeen surprisingly discovered that the insulating properties of a paperlayer 10 are enhanced when the insulating additives 12 are concentratedon one face of the paper 10 versus distributed substantially uniformlythroughout the thickness.

In FIG. 13C, another procedure is shown so as to result in a non-uniformdistribution of insulating particles 12 within an insulated paperproduct 100/100′. As shown in FIG. 13C, a second head box 204 may beused to deposit a layer of insulating mater 12 and optional fibers ontop of a lower layer of fibers (e.g., furnish) as the combined furnishproceeds along moving wire 206.

In FIG. 13D, another procedure is shown so as to result in a non-uniformdistribution of insulating particles 12 within an insulated paperproduct 100/100′. As shown in FIG. 13D, a third head box 204 may be usedto deposit a layer of insulating mater 12 and optional fibers on top ofa lower layer of fibers (e.g., furnish) as the combined furnish proceedsalong moving wire 206.

In FIG. 13E, another procedure is shown so as to result in a non-uniformdistribution of insulating particles 12 thin an insulated paper product100′. As shown in FIG. 13E, a first and a second head box 204 may beused to form two plies of fiber. A middle layer containing insulatingmaterial 12 is deposited as a liquid via a slot-die coater 261, or via aspray boom 262, or as a solid via a shilling roller 263. In 13E, the toplayer of pulp is first cast onto a separate wire 206, and thentransferred onto the middle layer of the non-uniform composite 100′. Theslot-die coaters 261 are well known, being similar to curtain coaters.Slot-die coaters 261 may include an agitation means (not shown) withinthe head 265 to ensure that feed is consistent and settling is avoided.More advanced slot-die coaters 261 include such inventions as theHydra-Sizer technology supplied by GL&V Pulp & Paper Group,Lawrenceville Ga.

In FIG. 13F, another procedure is shown so as to result a non-uniformdistribution of insulating particles 12 within an insulated paperproduct 100′. As shown in FIG. 13F, a nozzle 229 is used to feed pulp 11into the gap 268 between a vacuum roll 267 and a forming felt 206. Amiddle layer containing insulating material 12 is deposited as a slurryin layer 20. In 13F, the top layer of pulp 11 is applied by a secondhead box nozzle 229. Such nozzle pulp applicators 229 are described inU.S. Pat. No. 5,645,689 entitled “Multilayer Headbox” to Voith SulzerPapiermaschinen GmbH. Furthermore, Inventia disclose ‘Aq-Vane’technology for preventing mixing of layers as they are delivered by amulti-layered head. Aq-Vane incorporates an interstitial layer of waterbetween layers of pulp as they are laid down. “Multi-layer technology inpapermaking” by Daniel Soderberg, of Innventia, and the KTH RoyalInstitute of Technology, Stockholm: Presentation at the MarcisWallenberg Prize Symposium, Stockholm, Sweden, Oct. 2, 2012.

FIG. 13G depicts another method of making an insulated paper product100′ with non-uniform cross section containing an uneven distribution ofinsulating material 12. A multi-layer headbox 204 is used to put downthe first two layers (e.g., each of which independently comprises pulp11 and/or insulating material 12) on a forming wire 206, which are thenpressed with felt. Consecutive layers (e.g., layers 3 and 4, each ofwhich independently comprises pulp 11 and/or insulating material 12) areadded followed by felt presses after each additional layer.

Methods of making insulated paper products 100/100′/100″ of the presentinvention may further comprise forming one or more corrugated or flutedlayers of material 10/100/100′/100″ as shown in FIGS. 14-18B. Each ofthe corrugated or fluted layers of material may contain or be free frominsulating material 12. As shown in FIG. 14, a paper layer 10 (orlaminate 100) may proceed between cross-direction flute-forming rollers214 having cross-direction (CD) undulations 215 thereon so as to formcross-directional (CD) flutes 216 within the exemplary paper product 10.FIG. 15 depicts a cross-sectional view of the exemplary cross-direction(CD) flute-forming rollers 214 used in the process step shown in FIG. 14as viewed along line 15-15 shown in FIG. 14.

In other embodiments shown in FIGS. 16-17, a paper layer 10 (or laminate100) may proceed between machine-direction (MD) flute-forming rollers217 having machine-direction (MD) undulations 218 thereon so as to formmachine-directional (MD) flutes 219 within the exemplary paper product10. FIG. 17 depicts a close-up view of the exemplary machine-direction(MD) flute-forming rollers 217 used in the process step shown in FIG. 16as viewed in the machine direction (MD).

The method steps shown in FIGS. 14-17 may be used to form corrugatedpaper products 100″ of the present invention such as those shown inFIGS. 18A-18B. As shown in FIG. 18A, exemplary corrugated paper products100″ comprises two fluted layers 10 with both fluted layers havingeither (i) cross-directional flutes 216 or (ii) machine-directionalflutes 219 within each layer 10 of the exemplary corrugated paperproducts 100″. As shown in FIG. 18B, exemplary corrugated paper products100″ comprises two fluted layers 10 with one fluted layers havingcross-directional flutes 216 and the other fluted layer 10 havingmachine-directional flutes 219 within the exemplary corrugated paperproducts 100″.

Typically, in double-walled corrugated card (FIG. 18A), the flutes runin the same direction, namely, the cross-direction. The medium board 10is fluted by first steaming (i.e., at location 410), then runningthrough heated cross-direction flute-forming rollers 214 that impartcross-directional flutes 216 within the medium board 10. Crossing theflutes in the final double wall may help reduce thermal transfer viaconvection mechanisms. It will also impart additional strength to themedium hoard 10 due to the cross-directional flutes 216.

The methods of using the insulated paper products 10/100/100′/100″ ofthe present invention may comprise insulating food, medicines, etc. fromhot or cold environments. In some embodiments, the method may simplycomprise placing an item (e.g., food, medicines, etc.) within aninsulated paper product 10/100/400′/100″ of the present invention (e.g.,putting hot coffee in a cup of the present invention). In otherembodiments, the method may comprise placing an item (e.g., food,medicines, etc. within an insulated paper product 10/100/100′/100″ ofthe present invention (e.g., a box), and sealing the insulated paperproduct 10/100/100′/100″ for transport.

As discussed herein, methods of using the insulated paper products10/100/100′/100″ of the present invention may involve insulating an item(e.g., food, medicines, etc.) from hot or cold environments, wherein theitem (e.g., food, medicines, etc.) is placed or packaged within aninsulated paper product 10/100/100′/100″ that has a conventional shape,such as a cup or box. In other words, the insulated paper products10/100/100′/100″ of the present invention take the place or conventionalitems such as cups and boxes so as to provide one or more advantages asdiscussed above. As discussed herein, the insulated paper products10/100/100′/100″ of the present invention may have a variety of shapesand configurations similar to many conventional items such as cups andboxes.

During use, the insulated paper products 10/100/100′/100″/60 of thepresent invention desirably provide/have one or more of the followingfeatures/properties in addition to providing insulating properties:

(1) Moisture Resistance: Desirably, the insulated paper products10/100/100′/100″/60 of the present invention (e.g., a box 61) can beplaced into a freezer and then taken out and stacked at roomtemperature. Such a process usually leads to the insulated paper product10/100/100′/100″/60 (e.g., a box 61) “sweating” through condensation inthe warm air condensing on the surface of the insulated paper product10/100/100′/100″/60 (e.g., a box 61). In this regard, it is advantageousfor the insulated paper product 10/100/100′/100″/60 (e.g., a box 61) tobe resistant to moisture ingress. Multiple different additives can beused to reduce the propensity of the insulated paper product10/100/100′/100″/60 (e.g., a box 61) to absorb moisture and weaken whenmoist. For example, perlite 12 is more hydrophobic than paper fibers 11,so the incorporation of perlite 12 into a paper layer 10 renders thepaper layer 10 less absorbent. Further, the adhesive 40 that bondsflutes to liner board (see, FIGS. 6A-6D) can be made moisture resistantby adding a moisture resistant adhesive resin, such as Coragum SRavailable from Ingredion, Westchester Ill. In addition, a hydrophobictreatment can be applied to the exterior of the insulated paper product10/100/100′/100″/60 (e.g., a box 61). Moreover, a chemical cross-linkingagent or reactive resin (e.g. a methylol melanine) may be applied to theinsulated paper product 10/100/100′/100″/60 (e.g., a box 61), so that itis less sensitive to moisture. Lastly, paper fiber 11 may be treatedwith rosin, and then aluminum sulfate can be added to the furnish toimpart hydrophobicity to the paper layer 10. Alternatively, a wax may beadded to impart hydrophobicity.

While undesirable from an environmental and recycling perspective, athin layer of low density polyethylene (PE) may also be coated ontopaper layer 10, fiberboard 21/22/23, and card stock to impart oil andwater resistance, as is common practice in the fast food and hot & coldbeverage retail industry. In recent years, the paper industry hasexperienced increased pressure to seek alternatives to PE liners andlinings for packaging, leading the chemical industry to innovate newcoatings that impart grease and water resistance while being repulpable.US 2019/0077537 to Georgia Pacific Bleached Board LLC teaches the use ofseveral different coatings to impart resistance to water and lipidfluids to paper without the use of PE film, including Epotal 5440(BASF), Rhoplex P-376 (Dow), Diofan B204 (Solvay), Barrier-Grip 9471A(IGI), and Daran SL143 (Owensboro). These coatings were combined toimpart heat seal-ability as well as water proofing to paper beveragecups.

(2) Temperature History and Monitoring: In some embodiments, theconsumer may wish to be reassured that the insulated paper product10/100/100′/100″/60 (e.g., a box 61) contents have not been exposed tohigh temperatures. To this end, a temperature sensor may be included,such as: (a) a biodegradable and biocompatible temperature sensor may beincluded in the insulated paper product 10/100/100′/100″/60 (e.g., a box61), for instance, the biodegradable microsensor for food monitoring asdisclosed in NASA Tech Briefs Vol 42 No. 7, July 2018. The biosensorslowly dissolves in 1% saline solution; (b) a thermochromic material maybe included in the insulated paper product 10/100/100′/100″/60 (e.g., abox 61), such that once the temperature rises above a certaintemperature, the color changes, and the consumer is warned. Thethermochromic material can be reversible or irreversible. The ink couldalso be reversible, however, with a large hysteresis loop, so that thecolor change is meta-stable. Such inks are used in Pilot® Frixion® ballpen inks, which change from black to colorless upon warming; (c) theformation of condensation and the production of moisture when frozenmaterials are thawed can be taken advantage of, if a highly visible fooddye is included within the structure of the insulated paper product10/100/100′/100″/60 (e.g., a box 61). When moisture hits the insulatedpaper product 10/100/100′/100″/60 (e.g., a box 61), the dye dissolvesand stains the insulated paper product 10/100/100′/100″/60 (e.g., a box61) as a warning.

(3) Food Spoilage Sensors: In some embodiments, the insulated paperproducts 10/100/100′/100″/60 (e.g., a box 61) may further comprise: (a)a biodegradable microsensor for food monitoring as disclosed in NASATech Briefs Vol 42 No. 7, July 2018 can be configured to detect spoilinggasses, such as methane, hydrogen sulfide, methyl mercaptan, furfurylmercaptan, indole, cadaverine, isovaleric acid, skatol, and othermalodorous materials; and (b) certain colorants react with sulfides andamines, such as Michler's Hydrol Blue, which changes from blue tocolorless when exposed to low levels of hydrogen sulfide and amines.Furthermore, Sensor Technology published within NASA Tech BriefsSeptember 2018 describes a printable nanostructured conductive polymerwireless sensor that detects food spoilage by identifying odorsemanating from bad meat, first described in American Chemical Societypublication Nano Letters.

(4) Freezer to Microwave: For smaller packages, an added feature may bethat the insulated paper product 10/100/100′/100″/60 (e.g., a box 61)can be removed from a freezer and placed directly inside a microwaveoven. In these embodiments, the insulated paper product10/100/100′/100″/60 (e.g., a box 61) would need to be microwavetransparent. Optionally, the insulated paper product 10/100/100′/100″/60(e.g., a box 61) may contain a microwave susceptor.

(5) Boxes with Reduced Edge Effects: 90° bends in cardboard pinches thecardboard at those points, leading to potential heat loss at the foldededges. Boxes 61 of the present invention (e.g., formed from insulatedpaper product 10/1001100′/100″) can be designed that replace 90° cornerswith two 45° corners, to help minimize the losses.

(6) Transient Aluminized layer for Low Emissivity: Addition of a thinaluminized coating 30 onto the paper (e.g., paper layer 10 and/orinsulated paper product 100/100′ and/or corrugated paper product 100″and/or storage container 60) and/or onto the perlite 12 to loweremissivity. Aluminum has a very low emissivity and may be applied tovarious materials through a process called sputtering, or by vapordeposition. In this process, aluminum atoms traverse a vacuum andcondense onto the surface of another material (e.g., paper layer 10).Many thermal blankets are made via a process like this. Perliteparticles 12, as well as other types of particles, may be coatedpartially or totally in aluminum via these types of process. Paper orpaper fibers 11 may also be metallized by an aluminum coating by similarprocesses. Aluminum foil and metalized plastic films do not re-pulp andhave to be removed from the OCC and later waste streams, so thesematerials are not preferred in some embodiments of the presentinvention.

However, it is possible to incorporate a chelating agent in anotherlayer of the packaging (e.g., box 61), or for instance in the adhesive,or in one of the coatings. Such a chelating agent would function toremove the aluminum during a pulping process. Chelating agents mayinclude oxalic acid and oxalate salts. EDTA (ethylene diaminetetraacetic acid) and its various salts, salicylate, sodiumhexametaphosphate and other materials. In this way, the aluminum couldbe removed. Soluble aluminum salts are already used in papermaking forinstance as a flocculant for fines, as well as in combination with rosinsoap to impart water resistance.

(7) Odor Control and Taint of Foodstuffs: A concern with packaging andshipping of foodstuffs is taint and odor. This may arise from theinherent smell of virgin or recycled card, or it could arise when onepackage containing a strongly odorous material is placed in contact oradjacent to a package containing a food, beverage, drug, or tobaccoproduct. There may be several ways to mitigate odor and taint offoodstuffs by incorporating materials into the paper structure. Forinstance, transition metal ion modified silica nanoparticles such asthose described in U.S. Pat. No. 7,976,855 are able to efficientlycapture malodorous chemicals such as mercaptans, carboxylic acids, amineand other odors. U.S. Pat. No. 8,168,563 teaches that silicananoparticles may be modified by reaction with terminalaminoalkylthrimethoxysilanes and then with copper II ions to furtherenhance the odor capturing capabilities. Molecular sieves may also beincluded to sequester low molecular weight odor forming molecules suchas hydrogen sulfide and zeolites to sequester ammonia and amine odors.Activated carbon was also found to impart thermal insulation, and wouldalso be anticipated to absorb multiple odors. Activated carbon tends tobe acidic in nature, and so may be especially good at taking up basicand weakly basic odors such as ammonia and amine odors. More complexodors also have an affinity for activated carbon, including mercaptan,thiol, and aromatic odors. Cyclodextrins, such as β-cyclodextrin orγ-cyclodextrin and their derivatives may also be incorporated for theirodor absorbing properties. One or more of these materials/features couldbe incorporated into any of the here-in described paper layer 10 and/orinsulated paper product 100/100′ and/or corrugated paper product 100″and/or storage container 60 to modify and/or minimize any odors present.

Odor transmission from one package to another, or from one good toanother may also be mitigated through the use of barrier materials. Asone object of the present invention is repulpability of packaging,aluminum foil, PE or PET film, and other synthetic materials would notbe consistent with some embodiments of the present invention. However,some materials that provide thermal insulation have a microscopic flakemorphology, such as mica and coated mica, and these materials may beuseful for effectively blocking the transport of low and high MW malodorcausing materials from ingress into packages (e.g., comprising or formedfrom insulated paper product 10/100/100′/100″) of the present invention.

(8) Fiber Blend, Recycling, and Strength: Short length fibers tend tocome from refined hardwood, while longer fibers conic from softwood. Agood ratio of 75% softwood 25% hardwood balances the properties of thetwo types of fiber, optimizing tensile strength. Recently, hemp fibershave come under increasing attention as a paper additive. Hemp fibersare far longer than other pulp fibers, help increase strength due toincreasing contact points and bonding, and so may be subjected tomultiple recycling steps far more than regular wood fibers. Hemp fibers,being much longer than softwood may be recycled around 40 times vs. 6for other types of fiber. One or more of these materials/features couldbe incorporated into any of the here-in described insulated paper layer10 and/or insulated paper product 100/100′ and/or corrugated paperproduct 100″ and/or storage container 60.

In order to increase the ability of wood fibers to bond more throughsurface interactions, additional processes may be used to furtherfibrillate the fibers. For instance, the fibers may be subjected to anextreme high-shear environment, such as a colloid mill. The high sheerenvironment of two plate spinning in contact fibrillates cellulose fiberaggregates, increasing bonding, as well as the propensity to retainfiller solids. Other ways to fibrillate the fiber can include prolongedbeating in a mechanical Hollander pulp beater such as disclosed in theU.S. Pat. No. 1,883,051 or by high-sheer mixing, high-speed mixing, ormedia milling. Fibrillated cellulose may increase porosity of the paperand paper strength due to enhanced bonding area between fibers. Otherways to increase strength is by including nanocellulose into the paperformulation. One or more of these materials/features could beincorporated into any of the here-in described paper layer 10 and/orinsulated paper product 100/100′ and/or corrugated paper product 100″and/or storage container 60.

(9) Water Resistance Repulpability: Rosin is often used as part of atwo-part system to impart moisture resistance in paper (e.g., paperlayer 10 and/or insulated paper product 100/100′ and/or corrugated paperproduct 100″ and/or storage container 60). The second part is postaddition of aluminum salt solutions—e.g. aluminum chloride or aluminumsulfate. The aluminum reacts with the rosin soap to make a hydrophobiccoating, which may impact repulpability yield. However, including achelating agent somewhere in another component of the paper product mayremove the aluminum from the rosin, thereby increasing the repulpabilityyield. Other areas of the paper that could carry the chelating agent mayinclude the starch adhesive, and internal layer for instance, the flutedmedium, or an inner layer of the composite. Vapor-Guard R5341B orBarrier Grip 9471A (The International Group Inc., Titusville Pa.) arealso useful as barrier coatings that provide the paper with a degree ofgrease and water resistance, and are described along with other suitablematerials in Georgia Pacific Patent Application Publication No.US2019/0077537.

The present invention is further described by the following additionalembodiments, examples, and claims. It should be understood that anyfeature and/or component described herein may be present alone or incombination with any other feature and/or component or combination offeatures and/or components described herein to form the here-indescribed paper layer 10 and/or insulated paper product 100/100′ and/orcorrugated paper product 100″ and/or storage container 60 of the presentinvention. It should be further understood that the numbered embodimentsprovided below describe many embodiments of the present invention, someclaimed and some unclaimed. Even though some of the features in thenumbered embodiments provided below may not be claimed, the unclaimedfeature(s) in the numbered embodiments provided below do form part ofthe present invention, and may optionally be incorporated into anyclaimed product.

Additional Embodiments

Insulated Paper Products

-   1. An insulated paper product 100 comprising: one or more paper    layers 10 and insulating material 12, wherein (1) when two or more    paper layers 10 are present, the two or more paper layers 10 form an    integral paper product 100′, and (2)(a) at least one of (i) one    layer 20 in combination with said one or more paper layers 10    comprises said insulating material 12 and (ii) one paper layer 10    within said one or more paper layers 10 has a non-uniform    distribution of insulating material 12 therein, or (2)(b) the    integral paper product 100′ itself has a non-uniform distribution of    insulating material 12 therethrough. Each paper layer 10 may further    comprise one or more additives, other than insulating material 12,    the one or more additives including, but are not limited to,    flocculants and retention aids such as high molecular weight    poly(acrylamide), polyethylene imine), cationic guar gum, and other    cationic polymers; additives to provide water resistance (e.g., wax,    synthetic latexes and resins): or any combination thereof.-   2. The insulated paper product 100 of embodiment 1, wherein the one    or more paper layers 10 comprises a single paper layer 10, and the    single paper layer 10 has a non-uniform distribution of insulating    material 12 therein.-   3. The insulated paper product 100 of embodiment 2, wherein at least    one outer surface 13/15 of the single paper layer 10 comprises a    layer of insulating material 12. See, FIGS. 2A-2B.-   4. The insulated paper product 100 of embodiment 2 or 3, wherein the    non-uniform distribution of insulating material 12 comprises a layer    16 of insulating material 12 within the single paper layer 10    positioned away from opposite outer surfaces 13/15 of the single    paper layer 10. See, FIG. 2C.-   5. The insulated paper product 100 of any one of embodiments 2 to 4,    wherein the non-uniform. distribution of insulating material 12    comprises a layer 16 of insulating material 12 within the single    paper layer 10 positioned away from opposite outer surfaces 13/15 of    the single paper layer 10 and centrally located within the single    paper layer 10. See, FIG. 2C.-   6. The insulated paper product 100 of any one of embodiments 1 to 5,    wherein said insulated paper product 100 comprises at least one    layer 20 in combination with said one or more paper layers 10 with    said at least one layer 20 comprising said insulating material 12.    See, for example, FIGS. 68 and 6D, and FIG. 12-   7. The insulated paper product 100 of embodiment 1, wherein the one    or more paper layers 10 comprises two or more paper layers 10, and    the integral paper product 100′ itself has a non-uniform    distribution of insulating material 12 therethrough. See, for    example, FIGS. 4A-4F and 6B-6D.-   8. The insulated paper product 100′ of embodiment 7, wherein one or    more paper layers 10 within said integral paper product 100′    comprises insulating material 12.-   9. The insulated paper product 100′ of embodiment 7 or 8, wherein    the non-uniform distribution of insulating material 12 within said    integral paper product 100′ comprises (i) at least one paper layer-   10. with insulating material 12 therein and (ii) at least one paper    layer 10 substantially free of the insulating material 12. See, for    example, FIGS. 4A and 6B-6D.-   10. The insulated paper product 100′ of embodiment 9, wherein the at    least one paper layer 10 with insulating material 12 therein has a    substantially uniform distribution of the insulating material 12    within the at least one paper layer 10 with insulating material 12    therein. See again, for example, FIGS. 4A and 6B-6D.-   11. The insulated paper product 100′ of embodiment 7 or 8, wherein    all paper layers 10 within said integral paper product 100′ comprise    insulating material 12. See, for example, FIGS. 48-4E.-   12. The insulated paper product 100′ of any one of embodiments 7 to    11, wherein the non-uniform distribution of insulating material 12    comprises a layer 20 of insulating material 12 between the two or    more paper layers 10. See, FIG. 12.-   13. The insulated paper product 100′ of any one of embodiments 7 to    12, wherein the integral paper product 100′ comprises x paper layers    10 and (x−1) layers 20 of insulating material 12 between the x paper    layers 10.-   14. The insulated paper product 100′ of any one of embodiments 7 to    13, wherein the non-uniform distribution of insulating material 12    comprises a layer 20 of insulating material 12 along an outer    surface 13/15 of the integral paper product 100′.-   15. The insulated paper product 100′ of any one of embodiments 7 to    14, wherein the non-uniform distribution of insulating material 12    comprises a layer 20 of insulating material 12 along both outer    surfaces 13/15 of the integral paper product 100′.-   16. The insulated paper product 100′ of any one of embodiments 7 to    15, wherein the integral paper product 100′ comprises from two to 24    paper layers 10.-   17. The insulated paper product 100′ of any one of embodiments 7 to    16, wherein (i) any one of the two or more paper layers 10 or (ii)    any combination of paper layers 10 within the two or more paper    layers 10 each independently comprises the single paper layer 10 of    any one of embodiments 2 to 5.-   18. The insulated paper product 100 of any one of embodiments 1 to    17, wherein the insulated paper product 100 comprises a    void-containing insulated paper product 100″.-   19. The insulated paper product 100 of embodiment 18, wherein the    void-containing insulated paper product 100″ comprises voids 19    within at least one paper layer 10, the voids 19 being encapsulated    by a material other than paper (e.g., a paper layer 10 containing    hollow beads/particles (not shown)).-   20. The insulated paper product 100 of embodiment 18 or 19, wherein    the void-containing insulated paper product 100″ comprises voids 19    within at least one paper layer 10, the voids 19 being encapsulated    by paper (e.g., a paper layer 10 containing air pockets 19 therein,    possibly formed via a molding process or a process in which a    void-forming material is removed from the paper layer 10). See,    FIGS. 5-6D.-   21. The insulated paper product 100 of any one of embodiments 18 to    20, wherein the void-containing insulated paper product 100″    comprises a corrugated paper product 100″.-   22. The insulated paper product 100 of any one of embodiments 7 to    21, wherein the integral paper product 100′ comprises (i) a first    linerboard layer 21 comprising one or more first paper layers    10/100/100′, (ii) a second linerboard layer 22 comprising one or    more second paper layers 10/100/100′, and (iii) (a) a fluted paper    layer 23 comprising one or more fluted paper layers 10/100/100′    or (b) a honeycomb layer (not shown) positioned between the first    linerboard layer 21 and the second linerboard layer 22, and each    of (i) said first linerboard layer 21, (ii) said second linerboard    layer 22, and (iii) (a) said fluted paper layer 23 or (b) said    honeycomb layer (not shown) may independently comprise insulating    material 12 therein or thereon.-   23. An insulated paper product 100 comprising a corrugated integral    paper product 100″, said corrugated integral paper product 100″    comprising: a first linerboard layer 21 comprising one or more first    paper layers 10/100/100′, a second linerboard layer 22 comprising    one or more second paper layers 10/100/100′, and (a) a fluted paper    layer 23 comprising one or more fluted paper layers 10/100/100′    or (h) a honeycomb layer (not shown) positioned between the first    linerboard layer 21 and the second linerboard layer 22, wherein (i)    said first linerboard layer 21, (ii) said second linerboard layer    22, and (iii) (a) said fluted paper layer 23 or (b) said honeycomb    layer (not shown) may each independently comprise insulating    material 12 therein or thereon.-   24. The insulated paper product 100 of embodiment 22 or 23,    wherein (a) said fluted paper layer 23 or (b) said honeycomb layer    (not shown) provides pockets of air 19 between said first linerboard    layer 21 and said second linerboard layer 22.-   25. The insulated paper product 100 of embodiment 24, wherein said    pockets of air 19 represent from about 20 to 80 volume percent of a    total volume occupied by (a) said fluted paper layer 23 or (b) said    honeycomb layer (not shown)(i.e., a total volume between innermost    opposing surfaces 25/27 of said first linerboard layer 21 and said    second linerboard layer 22). See, for example. FIG. 6A.-   26. The insulated paper product 100 of any one of embodiments 22 to    25, further comprising an adhesive 40 that bonds portions of (a)    said fluted paper layer 23 or (h) said honeycomb layer (not shown)    to portions of said first linerboard layer 21 and said second    linerboard layer 22. Suitable materials for adhesive 40 include, but    are not limited to, starch adhesives, synthetic latex adhesives such    as poly(vinyl acetate), natural rubber latex, modified starches,    hydrocolloids such as hydroxypropylcellulose,    carboxymethylcellulose, and other water soluble polymers such as    poly(vinyl alcohol). A cross-linking agent may also be added to the    adhesive to avoid potential swelling of the adhesive and weakening    of the bonds when wet. Flocculants and retention aids may also be    included such as high molecular weight poly(acrylamide),    poly(ethylene imine), cationic guar gum, and other cationic    polymers. As discussed herein, in some embodiments, adhesive 40 is    at least partially filled with one or more of the herein disclosed    insulating materials 12.-   27. The insulated paper product 100 of embodiment 26, wherein said    adhesive 40 has insulating material 12 dispersed therein.-   28. The insulated paper product 100 of any one of embodiments 22 to    27, wherein each of (i) said first linerboard layer 21, (ii) said    second linerboard layer 22, and (iii) (a) said fluted paper layer 23    or (b) said honeycomb layer (not shown) independently comprises the    insulated paper product 100 of any one of embodiments 1 to 6 or the    integral paper product 100′ recited in any one of embodiments 7 to    20.-   29. The insulated paper product 100 of any one of embodiments 22 to    27, wherein each of (i) said first linerboard layer 21, (ii) said    second linerboard layer 22, and (iii) (a) said fluted paper layer 23    or (b) said honeycomb layer (not shown) is substantially free of    insulating material 12.-   30. The insulated paper product 100 of any one of embodiments 22 to    29, wherein the integral paper product 100′ comprises said fluted    paper layer 23.-   31. The insulated paper product 100 of any one of embodiments 22 to    29, wherein the integral paper product 100′ comprises said honeycomb    layer (not shown).-   32. The insulated paper product 100 of any one of embodiments 1 to    31, wherein the insulated paper product 100′ further comprises one    or more non-paper layers 20/30. As used herein, the term “non-paper    layer” is used to describe a layer that contains less than 15 wt %    paper pulp or cellulosic fiber, and typically contain 0 wt % to less    than 5.0 wt % paper pulp or cellulosic fiber. Conversely, as used    herein, the term “paper layer” (such as each paper layer 10) is used    to describe a layer that contains 15 wt % or more paper pulp or    cellulosic fiber, and typically contains greater than 15 wt % up to    100 wt % paper pulp or cellulosic fiber (or any value, between 15 wt    % and 100 wt %, in multiples of 0.1 wt %, e.g., 50.0 wt %, or any    range of values between 15 wt % and 100 wt %, in multiples of 0.1 wt    %, e.g., from 40.1 wt % to 70.2 wt %).-   33. The insulated paper product 100 of embodiment 32, wherein the    one or more non-paper layers 20/30 comprise a gypsum layer, a    clay-containing layer, a polymer coating, a pigment-containing    layer, a fabric layer (e.g., a nonwoven, woven or knit fabric    layer), a fiber-reinforcement layer (e.g., a layer of unidirectional    fibers), a layer of insulating material 12, a metal film layer, a    foam layer, or any combination thereof. One or more of the non-paper    layers 20/30 may be added to the insulated paper product 100 in    order to provide a desire property such as lower (or higher)    emissivity, lower (or higher) thermal conductivity, enhanced    water-repellency, an aesthetically pleasing color and/or texture, or    any combination thereof.-   34. The insulated paper product 100 of embodiment 32 or 33, wherein    the one or more non-paper layers 20/30 comprise a gypsum layer (not    shown).-   35. The insulated paper product 100 of any one of embodiments 32 to    34, wherein the one or more non-paper layers 20/30 comprise a    clay-containing layer 30, a coating 30 that provides a lower or    higher emissivity of the insulated paper product 100, a    pigment-containing layer 30, or any combination thereof. See, FIG.    6A.-   36. The insulated paper product 100 of any one of embodiments 32 to    35, wherein the one or more non-paper layers 20/30 comprise a    coating 30 that provides a lower emissivity and/or thermal    conductivity of the insulated paper product 100. See again, FIG. 6A.    In some embodiments, the coating 30 comprises bismuth oxychloride,    mica, zinc oxide, zinc sulfide, cadmium sulfide, bismuth vanadate,    or any mixture or combination thereof. In some embodiments, the    coating 30 comprises bismuth oxychloride, mica, zinc oxide, or any    mixture or combination thereof.-   37. The insulated paper product 100 of any one of embodiments 32 to    36, wherein the one or more non-paper layers 20/30 comprise at least    two non-paper layers 20/30.-   38. The insulated paper product 100 of any one of embodiments 1 to    37, wherein the insulating material 12 comprises perlite, perlite    coated with copper ions, expanded perlite, perlite hollow    microspheres (such as available from Richard. Baker Harrison Ltd.,    UK, or CenoStar Corporation (US), or Sil-Cel® microcellular aluminum    silicate filler particles made by creating a structure of    multicellular spherical bubbles comprising perlite, available from    Silbrico (US), Sil-Cel® microspheres are available in a range of    particle sizes, and may be coated or uncoated, or Dicaperl HP-2000    perlite microspheres, as sold by Dicalite (US), or flaked or milled    pulite (such as Dicaperl LD1006 also sold by Dicalite), porous    volcanic materials (such as pumice), vermiculite (including    MicroLite® vermiculite dispersions, available from Dicalite), hollow    expanded vermiculite, glass foams (such as Owens Corning), recycled    glass foams (such as manufactured by GrowStone Inc.), cellular glass    insulation materials, cenospheres (such as available from CenoStar    Corp.), glass bubbles (such as available from 3M under the trade    designations iM30K, iM16k, and K20, as well as Q-Cel glass), ceramic    microspheres, plastic microspheres, and synthetic hollow    microspheres (such as available from Kish Company Inc.), silica    aerogels (such as those available from Aspen Aerogels, and those    that may be incorporated into paints and coatings under the Enova®    and Lumira® brand from Cabot), microporous polyolefin-based aerogels    (such as disclosed in US Patent Application Publication No.    2016/0272777 to Aspen Aerogels Inc.), organic aerogels such as those    disclosed in PCT WO 2019121242 to Henkel AG & Co. KGAA which    comprise thiol-epoxy based aerogels, xerogels (i.e., collapsed    aerogels), seagels (i.e., microfoams made from agar and alginates).    foamed starch, foamed paper pulp, agar, foamed agar, alginates,    foamed alginates, bismuth oxychloride, metalized ceramics, metalized    fibers, cadmium yellow pigment (cadmium disulfide), or any    combination thereof. Examples of commercially available insulating    materials 12 include, but are not limited to, FOAMGLAS® products    commercially available from Owens Corning (Pittsburg Pa.); and    Growstone products commercially available from Growstone, LLC, a    subsidiary of Earthstone International Inc. (Santa Fe, N. Mex.).    Recycled glass suitable for use as insulating materials 12 is    typically crushed to a finely divided powder and mixed with a    blowing agent, e.g., carbon or limestone. It is then passed into a    furnace hot enough to begin to melt the glass. As the glass powder    particles begin to fuse, the blowing agent gives off a gas or vapor,    forming bubbles inside the glass. This generates a porous, mostly    closed cell glass foam, with high thermal and sound insulation    properties. Vermiculite may also be used as a suitable insulating    material 12. Vermiculite is a hydrous phyllosilicate mineral that    undergoes significant expansion when heated. Exfoliation occurs when    the mineral is heated sufficiently, and the effect is routinely    produced in commercial furnaces. Vermiculite is formed by weathering    or hydrothermal alteration of biotite or phlogopite.-   39. The insulated paper product 100 of any one of embodiments 1 to    38, wherein the insulating material 12 comprises perlite (e.g., in    the paper 10, the adhesive 40, the coating 30, and/or the emissivity    coating 30), aerogel (e.g., in the paper 10 and/or the adhesive 40),    glass bubbles (e.g., in the adhesive 40 and/or the coating 30),    activated carbon (e.g., in the paper 10, the adhesive 40, the    coating 30, and/or the emissivity coating 30), or any combination    thereof.-   40. The insulated paper product 100 of any one of embodiments 1 to    39, wherein the insulating material 12 comprises particles having an    average particle size of less than about 1000 microns (μm) (or any    average particle size greater than about 1.0 μm to less than about    1000 μm, in increments of 1.0 μm, e.g., 25 μm, or any range of    average particle size less than about 1000 μm, in increments of 1.0    μm, e.g., from about 50 μm to about 500 μm). For example, perlite    particles typically have an average particle size ranging from about    5.0 to about 150 μm, aerogel particles typically have an average    particle size ranging from about 10 to about 800 μm, and glass    bubble particles typically have an average particle size ranging    from about 10.0 to about 50 μm.-   41. The insulated paper product 100 of any one of embodiments 1 to    40, wherein the insulating material 12 comprises particles having a    multi-modal particle size distribution.-   42. The insulated paper product 100 of any one of embodiments 1 to    41, wherein paper layer 10 that contains insulating material 12    comprises from 15.0 weight percent (wt %) to 99.0 wt % fibers 11,    and from about 85.0 wt % to about 1.0 wt % insulating material 12,    based on a total weight of the paper layer 10. It should be    understood that a given paper layer 10 that contains insulating    material 12 can have (a) any weight percent of fibers 11 between    15.0 wt % and 99.0 wt % (i.e., in multiples of 0.1 wt %, e.g., 55.5    wt %, or any range of values between 15.0 wt % and 99.0 wt %, in    multiples of 0.1 wt %, e.g., from 35.6 wt % to 74.1 wt %).-   43. The insulated paper product 100 of any one of embodiments 1 to    42, wherein paper layer 10 that contains insulating material 12    comprises from 20.0 wt % to 75.0 wt % fibers 11, and from about 80.0    wt % to about 25.0 wt % insulating material 12, based on a total    weight of the paper layer 10.-   44. The insulated paper product 100 of any one of embodiments 1 to    43, wherein the insulating material 12 has a material density of    less than 1.0 gram per cubic centimeter (g/cm³), more typically,    less than 0.6 g/cm³. It should be understood that the insulating    material 12 can have any material density less than 1.0 g/cm³ such    as from greater than 0.01 g/cm³ to about 0.99 g/cm³ (or any value    between 0.01 and 0.99, in multiples of 0.01 g/cm³, e.g., 0.48 g/cm³,    or any range of values between 0.01 and 0.99, in multiples of 0.01    g/cm³, e.g., from 0.10 g/cm³ to 0.50 g/cm³).-   45. The insulated paper product 100 of any one of embodiments 1 to    44, wherein at least one layer 10 of said one or more paper layers    10 has a layer density of less than 1.0 g/cm³. It should be    understood that the at least one layer 10 can have any layer density    less than 1.0 g/cm³ such as from greater than 0.01 g/cm³ to about    0.99 g/cm³ (or any value between 0.01 and 0.99, in multiples of 0.01    g/cm³, e.g., 0.78 g/cm³, or any range of values between 0.01 and    0.99, in multiples of 0.01 g/cm³, e.g., from 0.20 g/cm³ to 0.60    g/cm³). It should be further understood that any number of layers 10    of said one or more paper layers 10 may have an independent layer    density, each of which is less than 1.0 g/cm³ (or any value between    0.01 and 0.99, in multiples of 0.01 g/cm³, e.g., 0.88 g/cm³, or any    range of values between 0.01 and 0.99, in multiples of 0.01 g/cm³,    e.g., from 0.15 g/cm³ to 0.55 g/cm³).-   46. The insulated paper product 100 of any one of embodiments 1 to    45, wherein said integral paper product 100+ has an integral paper    product density of less than 1.0 g/cm³. It should be understood that    the integral paper product 100′ can have any integral paper product    density less than 1.0 g/cm³ such as from greater than 0.01 g/cm³ to    about 0.99 g/cm³ (or any value between 0.01 and 0.99, in multiples    of 0.01 g/cm³, e.g., 0.77 g/cm³, or any range of values between 0.01    and 0.99, in multiples of 0.01 g/cm³, e.g., from 0.15 g/cm³ to 0.53    g/cm³).-   47. The insulated paper product 100 of any one of embodiments 1 to    46, wherein the insulated paper product 100 is molded to form a    three-dimensional object (e.g., a cup 62 or container 60).-   48. A storage container 60 comprising the insulated paper product    100 of any one of embodiments 1 to 47. See, FIGS. 19A-19C.-   49. The storage container 60 of embodiment 48, wherein the storage    container 60 comprises a storage volume 66 at least partially    surrounded by one or more container walls 68.-   50. The storage container 60 of embodiment 48 or 49, wherein the    storage volume 66 is completely surrounded by or surroundable (i.e.,    the storage container 60 can be configured to surround the storage    volume 66) by one or more container walls 68.-   51. The storage container 60 of embodiment 49 or 50, wherein the one    or more container 68 comprise the insulated paper product 100 of any    one of embodiments 1 to 47.-   52. The storage container 60 of any one of embodiments 49 to 51,    wherein the one or more container walls 68 comprise a gypsum layer,    a clay-containing layer, a polymer coating, a pigment-containing    layer, a bismuth oxychloride-containing layer, a mica containing    layer, an aerogel containing layer, a fabric layer (e.g., a    nonwoven, woven or knit fabric layer), a fiber-reinforcement layer    (e.g., a layer of unidirectional fibers), a layer of insulating    material 12, a metal film layer, a foam layer, a layer of air, a    coating that lowers an emissivity of the one or more container walls    (e.g., such as mica, bismuth oxychloride, zinc oxide, zinc sulfide,    kaolin clay, or cadmium sulfide), a coating that lowers a thermal    conductivity of the one or more container walls, a coating that    enhances a water-repellency of the one or more container walls such    as a wax, or a fluorocarbon, or a reactive cross-linking agent such    as an epoxy or a urethane, or a silicone-based coating, or one or    more coatings mentioned in U.S. Patent Application Publication No.    20191077537, or any combination thereof.-   53. The storage container 60 of any one of embodiments 48 to 52,    wherein the storage container 60 comprises a box 61.-   54. The storage container 60 of any one of embodiments 48 to 53,    wherein the storage container 60 comprises a container 62 for    temporarily housing a liquid (not shown).-   55. The storage container 60 of any one of embodiments 48 to 52 and    54, wherein the container 60 comprises a cup 62, a mug, a flask, or    a thermos 62. As shown in FIG. 19C, the storage container 60 may be    a hot beverage cup 62, which could replace both STYROFOAM® cups, as    well as lined paper cups along with the insulating paper ring    currently provided to prevent burning fingers of the person holding    the cup.-   56. The storage container 60 of any one of embodiments 48 to 52,    wherein the container 60 comprises a clam shell type box packaging    60 for hot food 80. Such a container may be made via molding pulp    using a vacuum forming machine. See, for example, FIG. 20.-   57. The storage container 60 of any one of embodiments 48 to 52,    wherein the container 60 comprises a salad container 60 for chilled    food 80. See, for example, FIG. 21.-   58. The storage container 60 of any one of embodiments 48 to 52,    wherein the container 60 comprises a padded envelope 60. See, for    example, FIG. 22.-   59. The storage container 60 of any one of embodiments 48 to 52,    wherein the container 60 comprises a shipping container 60. See, for    example, FIG. 23A. As shown in FIG. 23B, exemplary shipping    container 60 comprises (i) multiple thinner paper layers 10, each of    which includes insulating materials 12 incorporated therein,    optionally with (ii) a non-uniform distribution of material    particles 92 (which could be insulating material 12),    optionally (iii) air 90 or an insulative filler material between the    layers 10, and (iv) optionally coating(s) 30 on one or more of the    paper layers 10.-   60. The storage container 60 of embodiment 59, wherein the shipping    container 60 comprises shipping container walls 69 that comprise a    closed cell foam 30′. See, for example, FIG. 24. In this embodiment,    the closed cell foam 30′ may be a biodegradable foam 30′, for    instance a foamed starch such as GreenCell® sold by KIM Industries    Inc. Holt, Mich., or a foamed alginate, or pectin, or gelatin, or    agar material that has been foamed through one means or another, and    optionally chemically cross-linked to a certain extent. As shown in    FIG. 24, the shipping container 60 may include paper layers 10 that    may optionally include insulating material 12, and may also contain    a thermal barrier coating 30. The coating 30 could be designed to    reduce radiative heat transfer, or it could be designed to reduce    conductive heat transfer, or it could be designed to reduce both.-   61. The storage container 60 of any one of embodiments 48 to 60,    wherein the storage container 60 of dimensions 12″×10″×7″ is capable    of keeping a combination of 900 g cooked pork (or simulant) and 1800    g of frozen water gel packs (conditioned to −20° C. prior to placing    into the container) below 0° C. after 10 hours in an external    temperature of 23° C.-   62. A storage container 60 of any one of embodiments 48 to 61 or the    insulated paper product 100 of any one of embodiments 1 to 47,    further comprising a coating 30 on (i) an inner surface 63, (ii) an    outer surface 13/15, or (iii) both (i) and (ii) of the storage    container 60 or the insulated paper product 100, the coating 30    having a low thermal emissivity or thermal barrier property. As used    herein, the phrase “a low thermal emissivity” refers to a thermal    emissivity of less than 0.90, as measured using Thermal Emissivity    Method #3 Recommended by Flir Systems Inc. (described in the    “Example” section below). Suitable materials for use in a given    “emissivity coating” include, but are not limited to, bismuth    oxychloride, mica flakes, perlite, kaolin, and any combination    thereof (e.g., mica flakes partially or completely coated with    bismuth oxychloride).-   63. A storage container 60 of any one of embodiments 48 to 62 or the    insulated paper product 100 of any one of embodiments 1 to 47,    further comprising a coating 30 on (i) an inner surface 63, (ii) an    outer surface 13/15, or (iii) both (i) and (ii) of the storage    container 60 or the insulated paper product 100, the coating 30    having a Thickness Adjusted Delta T (TADT) heat transfer rate of    less than about 9° C. As used herein, the TADT is measured using the    Modified Lee's Disk Heat Transfer Rate Test Method (described in the    “Example 2” section below).-   64. A storage container 60 of any one of embodiments 48 to 63 or the    insulated paper product 100 of any one of embodiments 1 to 47,    further comprising a coating 30 on (i) an inner surface 63, (ii) an    outer surface 13/15, or (iii) both (i) and (ii) of the storage    container 60 or the insulated paper product 100, the coating 30    comprising clay particles, a colorant other than said clay    particles, or a combination thereof.-   65. A storage container 60 of any one of embodiments 48 to 64 or the    insulated paper product 100 of any one of embodiments 1 to 47,    further comprising a coating 30 on (i) an inner surface 63, (ii) an    outer surface 13/15, or (iii) both (i) and (ii) of the storage    container 60 or the insulated paper product 100, the coating 30    comprising one or more materials that increase the water resistance    of (i) the inner surface 63, (ii) the outer surface 13/15, or (iii)    both (i) and (ii) of the storage container 60 or the insulated paper    product 100.-   66. A storage container 60 of any one of embodiments 48 to 65 or the    insulated paper product 100 of any one of embodiments 1 to 47,    further comprising a coating 30 on (i) an inner surface 63, (ii) an    outer surface 13/15, or (iii) both (i) and (ii) of the storage    container 60 or the insulated paper product 100, the coating 30    water-proofing (i) the inner surface 63, (ii) the outer surface    13/15, or both (i) and (ii) of the storage container 60 or the    insulated paper product 100. By “waterproofing,” it is meant that    the outer surface 13/15 of the storage container 60 or the insulated    paper product 100 can be in contact with water for 24 hours and    maintain its structural integrity.-   67. A storage container 60 of any one of embodiments 48 to 66 or the    insulated paper product 100 of any one of embodiments 1 to 47,    further comprising a coating 30 on (i) an inner surface 63, (ii) an    outer surface 13/15, or (iii) both (i) and (ii) of the storage    container 60 or the insulated paper product 100, the coating 30    increasing a moisture absorption capacity of (i) the inner surface    63, (ii) the outer surface 13/15, or (iii) both (i) and (ii) of the    storage container 60 or the insulated paper product 100.

Methods of Making Insulated Paper Products

-   68. A method of making the insulated paper product 100 of any one of    embodiments 1 to 47, said method comprising: forming an insulated    paper product 100 comprising: one or more paper layers 10 and    insulating material 12, wherein (1) when two or more paper layers 10    are present, the two or more paper layers 10 form an integral paper    product 100′, and (2)(a) at least one of: (i) one layer 20 in    combination with the one or more paper layers 10 comprises the    insulating material 12 and (ii) one paper layer 10 within the one or    more paper layers 10 has a non-uniform distribution of insulating    material 12 therein, or (2)(b) the integral paper product 100′    itself has a non-uniform distribution of insulating material 12    therethrough.-   69. A method of making an insulated paper product 100, said method    comprising: forming an insulated paper product 100 comprising: one    or more paper layers 10 and insulating material 12, wherein (1) when    two or more paper layers 10 are present, the two or more paper    layers 10 form an integral paper product 100′, and (2)(a) at least    one of: (i) one layer 20 in combination with the one or more paper    layers 10 comprises the insulating material 12 and (ii) one paper    layer 10 within the one or more paper layers 10 has a non-uniform    distribution of insulating material 12 therein, or (2)(b) the    integral paper product 100′ itself has a non-uniform distribution of    insulating material 12 therethrough.-   70. The method of embodiment 68 or 69, wherein said forming step    comprises at least one papermaking step.-   71. The method of any one of embodiments 68 to 70, wherein said    forming step comprises incorporating the insulating material 12    within one or more paper layers 10 of the one or more paper layers    10.-   72. The method of embodiment 71, wherein said incorporating step    comprises forming a non-uniform distribution of the insulating    material 12 within at least one paper layer 10 of the one or more    paper layers 10.-   73. The method of embodiment 72, wherein the non-uniform    distribution of the insulating material 12 comprises a layer of    insulating particles 16 positioned proximate an outer surface of the    at least one paper layer within the one or more paper layers 10.-   74. The method of embodiment 72, wherein the non-uniform    distribution of the insulating material 12 comprises a layer of    insulating particles 16 positioned centrally within the at least one    paper layer within the one or more paper layers 10.-   75. The method of any one of embodiments 68 to 74, wherein said    incorporating step comprises forming a uniform distribution of the    insulating material 12 within at least one paper layer 10 of the one    or more paper layers 10.-   76. The method of any one of embodiments 68 to 75, wherein said    forming step comprises forming a layer 20 of the insulating material    12 on the one or more paper layers 10.-   77. The method of any one of embodiments 68 to 76, wherein said    forming step comprises incorporating a layer 20 of the insulating    material 12 between two or more paper layers 10.-   78. The method of any one of embodiments 68 to 77, wherein said    forming step comprises incorporating one or more additives, other    than the insulating material 12, into at least one paper layer 10    within the one or more paper layers 10. Suitable additives include,    but are not limited to, copper ions, waxes, synthetic (e.g.,    polymeric or glass) fibers, silica, surface modified silica,    transition metal surface modified silica, cyclodextrin, sodium    bicarbonate, silicones to impart grease and water resistance,    metalized ceramic particles, metalized fibers, cationic starches,    cationic polymers, such as cationic guar gum, polyethylene imine)    (e.g., poly(ethylene imine marketed as Polymin P and available from    Aldrich Chemical), fillers, sizes, binders, clays including    bentonite clay, kaolin clay, and other minerals, calcium carbonate,    calcium sulfate, and other materials that may be added to paper    products for different reasons, and any combinations thereof. The    filler may make the paper more receptive to printing, for instance,    or make the paper glossy. Many fillers have a density greater than    1.0 g/cm³. Flocculants and retention aids, may also be included such    as high molecular weight poly(acrylamide), poly(ethylene imine),    cationic guar gum, and other cationic polymers. Sizes and binders    may also be added to help provide strength to papers, and can    include starches, hydrocolloids, artificial and natural polymer    latexes, such as RHOPLEX® acrylic resins from Dow Chemical and    ROVENE® binders from Mallard Creek Polymers (Charlotte N.C.). Water    soluble polymers, such as polyvinyl alcohol), and poly(acrylic acid)    may also be added to the paper. Sometimes, water resistance on the    final box is required. Vapor-Guard R5341B or Barrier Grip 9471A (The    International Group Inc., Titusville Pa.) are useful as barrier    coatings that provide a given paper layer 10 with a degree of grease    and/or water resistance.-   79. The method of any one of embodiments 68 to 78, wherein said    forming step comprises forming at least one fluted paper layer 10    within the one or more paper layers 10. See, for example, FIGS.    6A-6D and 14-18B.-   80. The method of embodiment 79, wherein the at least one fluted    paper layer 10 has cross-directional flutes 216 therein.-   81. The method of embodiment 79 or 80, wherein the at least one    fluted paper layer 10 has machine-directional flutes 219 therein.-   82. The method of any one of embodiments 68 to 81, wherein said    forming step comprises bonding two or more paper layers 10 to one    another.-   83. The method of embodiment 82, wherein said bonding step comprises    a laminating step. See, for example, FIG. 10.-   84. The method of embodiment 82 or 83, wherein said bonding step    comprises an adhesion step. See, for example, FIGS. 6A-6D, wherein    adhesive 40 is used to bond paper layers 10/100′ to one another.-   85. The method of embodiment 84, further comprising incorporating    the insulating material 12 within an adhesive 40 using in said    adhesion step. See, for example, FIGS. 6B-6D.-   86. The method of any one of embodiments 79 to 85, further    comprising incorporating the insulating material 12 within one or    more voids e.g., air voids 90) of the at least one fluted paper    layer 10. See, for example. FIG. 6C.-   87. The method of any one of embodiments 68 to 86, wherein said    forming step comprises forming a wall structure comprising the one    or more paper layers 10 and at least one additional layer. The    additional layer could be a layer 20 of insulating material 12, a    coating 30 (e.g., a coating 30 that increases or decreases an    emissivity of a paper layer 10/100″ or an integrated product 100″),    a non-paper layer 30, a layer of air 90, or any combination thereof.    See, for example, FIGS. 6A-6D and 23A-24.-   88. The method of any one of embodiments 68 to 87, wherein said    forming step comprises forming a storage container 60.-   89. The method of embodiment 88, wherein the storage container 60    comprises the storage container 60 of any one of embodiments 48 to    67.-   90. The method of any one of embodiments 68 to 89, wherein said    forming step comprises forming at least one paper layer 10 within    the one or more paper layers 10 using recycled paper pulp.-   91. The method of any one of embodiments 68 to 90, wherein said    forming step comprises forming at least one paper layer 10 within    the one or more paper layers 10 using recycled pre-consumer scrap    cardboard. Pre-consumer scrap cardboard includes, but is not limited    to, trimmings from cutting boxes from a cardboard sheet, defective    box material and boxes, or any combination thereof.-   92. The method of any one of embodiments 68 to 91, wherein said    forming step comprises forming at least one paper layer 10 within    the one or more paper layers 10 using recycled insulated paper    product 100 of any one of embodiments 1 to 47, recycled storage    containers 60 of any one of embodiments 48 to 67, or any combination    thereof. For example, one method of making at least one paper layer    10 and a container 60 formed therefrom comprises forming a    corrugated structure 100″ with at least one outer ply/liner 21/22    that contains fiber 11 and insulating material 12, and a fluted    median ply/liner 23 without insulating material 12, comprising:    suspending cellulose fibers 11 in water to make paper pulp 11;    forming a fibrous first layer 10 from the pulp 11; suspending    cellulose fibers 11 in water, adding voided materials (e.g., hollow    insulating material 12), optionally adding surface active agents,    optionally adding a flocculent; forming this layer 10 on top of the    first layer of pulp 10; suspending cellulose fibers 11 in water to    make paper pulp 11; forming a fibrous top layer 10 on top of the    second layer 10; pressing and drying the resultant three-ply    insulated paper sheet 100′; optionally coating at least one of the    surfaces of the three-ply insulated paper sheet 100′ with a coating    30 selected from comprising aluminum, silver, mica, sericite, zinc    oxide, zinc sulfide, cadmium sulfide, bismuth oxychloride, bismuth    oxychloride coated mica, bismuth vanadate, gypsum, or combinations    thereof; passing a paper sheet 10 through a corrugator to make a    fluted layer 23 while adhering two insulated paper sheets 100′ as    liner boards 21/22 to the fluted layer 23 to form corrugated board    100″; optionally adding an additional fluted layer 23 and another    liner board 21 or 22 to make a double walled corrugated structure    100″, containing three insulated liner boards 21/22 and two fluted    layers 23; cutting the double walled corrugated structure 100″ into    the form/shape of a box 60; and allowing the off-cuts (e.g., scraps    from the cutting step) to be sent back to the repulping mill mixed    with off-cuts from non-insulating board. Another method of making at    least one paper layer 10 and a container 60 formed therefrom    comprises forming a corrugated structure 100″ with at least one    outer ply/liner 21/22 that contains a paper layer 10 and an    insulating material layer 20, and a fluted median ply/liner 23    without insulating material 12, comprising: suspending cellulose    fibers 11 in water to make paper pulp 11, and optionally adding a    flocculant; forming a fibrous first layer 10 from pulp 11;    suspending voided materials (e.g., hollow insulating material 12) in    water, optionally adding surface active agents, and optionally    adding a flocculent and/or a binder; forming this layer 20 on top of    the first layer 10 of pulp 11, through curtain coating, slot-die    coating, rod coating, spray application, etc.; suspending cellulose    fibers 11 in water to make paper pulp 11 optionally adding a    flocculant; forming a fibrous top layer 10 on top of the second    layer 20; pressing and drying the resultant insulated paper sheet    100′; optionally coating at least one of the surfaces of the    resultant insulated paper sheet 100′ with a coating 30 comprising    aluminum, silver, mica, sericite, zinc oxide, zinc sulfide, cadmium    sulfide, bismuth oxychloride, bismuth oxychloride coated mica,    bismuth vanadate, gypsum, or combinations thereof passing a paper    sheet 10 through a corrugator to make a fluted layer 23 while    adhering two insulated paper sheets 100′ as liner boards 21/22 to    the fluted layer 23 to form corrugated hoard 100″; optionally adding    an additional fluted layer 23 and another liner board 21 or 22 to    make a double walled corrugated structure 100″, containing three    insulated liner boards 21/22 and two fluted layers 23; cutting the    double walled corrugated structure 100″ into the form/shape of a box    60; and allowing the off-cuts (e.g., scraps from the cutting step)    to be sent back to the repulping mill mixed with off-cuts from    non-insulating board. Yet another method of making at least one    paper layer 10 and a container 60 famed therefrom comprises forming    a corrugated structure 100″ with at least one outer ply/liner 21/22    that contains fiber 11 and insulating material 12, and a fluted    median ply/liner 23 that comprises insulating material 12,    comprising: suspending cellulose fibers 11 in water to make paper    pulp 11; forming fibrous first layer 10 from the pulp 11; suspending    cellulose fibers 11 in water, adding voided materials (e.g., hollow    insulating material 12), optionally adding surface active agents,    optionally adding a flocculent; forming this layer 10 on top of the    first layer of pulp 10; suspending cellulose fibers 11 in water to    make paper pulp 11; forming a fibrous top layer 10 on top of the    second layer 10; pressing and drying the resultant three-ply    insulated paper sheet 100′; optionally coating at least one of the    surfaces of the three-ply insulated paper sheet 100′ with a coating    30 selected from comprising aluminum, silver, mica, sericite, zinc    oxide, zinc sulfide, cadmium sulfide, bismuth oxychloride, bismuth    oxychloride coated mica, bismuth vanadate, gypsum, or combinations    thereof; passing the resultant three-ply insulated paper sheet 100′    through a corrugator to make a fluted layer 23 while adhering two    insulated paper sheets 100′ as liner boards 21/22 to the fluted    layer 23 to form corrugated hoard 100″; optionally adding an    additional fluted layer 23 and another liner hoard 21 or 22 to make    a double walled corrugated structure 100″, containing three    insulated liner boards 21/22 and two fluted layers 23; cutting the    double walled corrugated structure 100″ into the form/shape of a box    60; and allowing the off-cuts (e.g., scraps from the cutting step)    to be sent back to the repulping mill mixed with off-cuts from    non-insulating board. Yet another method of making at least one    paper layer 10 and a container 60 formed therefrom comprises forming    a corrugated structure 100″ with at least one outer ply/liner 21/22    that contains a paper layer 10 and an insulating material layer 20,    and a fluted median ply/liner 23 with an insulating layer 20,    comprising: suspending cellulose fibers 11 in water to make paper    pulp 11, and optionally adding a flocculant; forming a fibrous first    layer 10 from pulp 11; suspending voided materials (e.g., hollow    insulating material 12) in water, optionally adding surface active    agents, and optionally adding a flocculent and/or a binder; forming    this layer 20 on top of the first layer 10 of pulp 11, through    curtain coating, slot-die coating, rod coating, spray application,    etc.; suspending cellulose fibers 11 in water to make paper pulp 11    optionally adding a flocculant; forming a fibrous top layer 10 on    top of the second layer 20; pressing and drying the resultant    insulated paper sheet 100′; optionally coating at least one of the    surfaces of the resultant insulated paper sheet 100′ with a coating    30 comprising aluminum, silver, mica, sericite, zinc oxide, zinc    sulfide, cadmium sulfide, bismuth oxychloride, bismuth oxychloride    coated mica, bismuth vanadate, gypsum, or combinations thereof;    passing the insulated paper sheet 100′ through a corrugator to make    a fluted layer 23 while adhering two insulated paper sheets 100′ as    liner boards 21/22 to the fluted layer 23 to form corrugated board    100″; optionally adding an additional fluted layer 23 and another    liner board 21 or 22 to make a double walled corrugated structure    100″, containing three insulated liner boards 21/22 and two fluted    layers 23; cutting the double walled corrugated structure 100″ into    the form/shape of a box 60; and allowing the off-cuts (e.g., scraps    from the cutting step) to be sent back to the repulping mill mixed    with off-cuts from non-insulating board.-   93. The method of any one of embodiments 68 to 92, wherein said    forming step comprises a molding step so as to form a    three-dimensional object from the one or more paper layers 10 or the    insulated paper product 100/100′ or the insulated paper product    having a corrugated structure 100″.-   94. The method of embodiment 93, wherein the molding step comprises    a pressure molding step, a thermoforming step, a vacuum forming    step, or any combination thereof.-   95. The method of any one of embodiments 68 to 94, wherein each    paper layer 10 that contains insulating material 12 comprises from    15.0 wt % to 99.0 wt % fibers 11, and from about 85.0 wt % to about    1.0 wt % insulating material 12, based on a total weight of the    paper layer 10.-   96. The method of any one of embodiments 68 to 95, wherein each    paper layer 10 that contains insulating material 12 comprises from    15.0 wt % to 80.0 wt % fibers 11, and from about 85.0 wt % to about    20.0 wt % insulating material 12, based on a total weight of the    paper layer 10.-   97. The method of any one of embodiments 68 to 96, wherein the    insulating material 12 has a material density of less than 1.0 g/cm³    (or any value between 0.01 g/cm³ and 0.99 g/cm³, in multiples of    0.01 g/cm³, e.g., 0.48 g/cm³, or any range of values between 0.01    g/cm³ and 0.99 g/cm³, in multiples of 0.01 g/cm³, e.g., from 0.10    g/cm³ to 0.50 g/cm³).-   98. The method of any one of embodiments 68 to 97, wherein at least    one layer 10 of the one or more paper layers 10 has a layer density    of less than 1.0 g/cm³ (or any value between 0.01 g/cm³ and 0.99    g/cm³, in multiples of 0.01 g/cm³, e.g., 0.78 g/cm³, or any range of    values between 0.01 g/cm³ and 0.99 g/cm³, in multiples of 0.01    g/cm³, e.g., from 0.20 g/cm³ to 0.75 g/cm³). It should be further    understood that any number of layers 10 of the one or more paper    layers 10 may have an independent layer density, each of which is    less than 1.0 g/cm³ (or any value between 0.01 g/cm³ and 0.99 g/cm³,    in multiples of 0.01 g/cm³, e.g., 0.44 g/cm³, or any range of values    between 0.01 g/cm³ and 0.99 g/cm³, in multiples of 0.01 g/cm³, e.g.,    from 0.18 g/cm³ to 0.85 g/cm³).-   99. The method of any one of embodiments 68 to 98, wherein the    integral paper product 100′ has an integral paper product density of    less than 1.0 g/cm³ (or any value between 0.01 g/cm³ and 0.99, g/cm³    in multiples of 0.01 g/cm³, e.g., 0.77 g/cm³, or any range of values    between 0.01 g/cm³ and 0.99 g/cm³, in multiples of 0.01 g/cm³, e.g.,    from 0.18 g/cm³ to 0.53 g/cm³).

Methods of Using Insulated Paper Products

-   100. A method of using the insulated paper product 100 of any one of    embodiments 1 to 47 or the storage container 60 of any one of    embodiments 48 to 67, said method comprising: insulating an object    via the insulated paper product 100 or the storage container 60.-   101. The method of embodiment 100, wherein the object is a surface.-   102. The method of embodiment 100, wherein the object is a food    item, a medicine, or any other item that is desirably kept at a cool    temperature (e.g., a temperature below room temperature or a    refrigerating temperature) or at an elevated temperature (e.g., a    temperature above room temperature or a hot-out-of-the-oven    temperature).-   103. The method of embodiment 100 or 102, wherein the object is a    food item.-   104. The method of any one of embodiments 100 to 103, wherein the    method uses the storage container 60 of any one of embodiments 48 to    67.-   105. The method of any one of embodiments 100 to 104, wherein the    method uses the storage container 60 and the storage container 60    comprises a box 61, a container 62 for temporarily housing a liquid    (not shown), a cup, a mug, a flask, or a thermos 62, a clam shell 60    for hot food 80 (See, for example, FIG. 20), a salad container 60    for chilled food 80 (See, for example, FIG. 21), a padded envelope    60 (See, for example, FIG. 22), a shipping container 60 (See, for    example, FIG. 23A), a shipping container 60 comprising shipping    container walls 69 that comprise a closed cell foam 30′ (See, for    example, FIG. 24), or any combination thereof. For example, in one    method of use, the method comprises a method of maintaining an    object at a controlled temperature comprising: heating or chilling    an object (e.g., food, medicine, meat, fish, salad, vegetables,    flowers, pharmaceuticals, biological specimens) to a pre-determined    temperature T; packaging the object inside any herein-described    storage container 60.-   106. The method of any one of embodiments 100 to 105, wherein the    storage container 60 of dimensions 12″×10″×7″ is capable of keeping    a combination of 900 g cooked pork (or simulant) and 1800 g of    frozen water gel packs (conditioned to −20° C. prior to placing into    the container) below 0° C. after 10 hours in an external temperature    of 23° C.-   107. The method of any one of embodiments 100 to 106, wherein the    insulated paper product 100 of any one of embodiments 1 to 47 or the    storage container 60 of any one of embodiments 48 to 67 further    comprises a coating 30 on (i) an inner surface 63, (ii) an outer    surface 13/15, or (iii) both (i) and (ii) of the storage container    60 or the insulated paper product 100, the coating 30 (a) having a    low thermal emissivity, (b) having a Thickness Adjusted Delta T    (TADT) heat transfer rate of less than about 9° C. As used herein,    the TADT is measured using the Modified Lee's Disk Heat Transfer    Rate Test Method (described in the “Example 2” section below), (c)    comprising clay particles, a colorant other than said clay    particles, or a combination thereof, (d) comprising one or more    materials that increase the water resistance of outer surface 13/15    of the storage container 60 or the insulated paper product 100, (e)    water-proofing the inner surface 63 and/or the outer surface 13/15    of the storage container 60 or the insulated paper product 100, (f)    increasing a moisture absorption capacity of the inner surface of    the storage container 60 or the insulated paper product 100, or any    combination of (a) to (f).-   108. The method of any one of embodiments 100 and 102 to 107,    further comprising transporting the object within the insulated    paper product 100 or the storage container 60.-   109. The method of any one of embodiments 100 and 102 to 108,    further comprising shipping the object within the insulated paper    product 100 or the storage container 60. For example, in one method    of use, the method comprises a method of shipping an object at a    controlled temperature comprising: chilling an object (e.g., food,    medicine, meat, fish, salad, vegetables, flowers, pharmaceuticals,    biological specimens) to below a spoiling temperature of the object;    packaging the chilled object inside any herein-described storage    container 60, along with frozen water gel packs, dry ice, etc.;    closing the container; placing the storage container 60 into a    vehicle (e.g., car, train, bus, airplane, etc.); transporting the    package to a pre-determined destination; removing the storage    container 60 from the vehicle; and delivering the storage container    60 to either the front door of a residence, or to the loading dock    of a distribution center, or the entrance of a restaurant, or the    receiving department of a business, wherein the temperature inside    the unopened storage container 60 remains below the food spoiling    temperature for at least 24 hours.-   110. The method of any one of embodiments 100 to 109, further    comprising repulping the insulated paper product 100 and/or the    storage container 60 after said insulating step, wherein at least    80% of the insulating filler is removed from the pulp during the    repulping operation.-   111. The method of any one of embodiments 100 to 110, further    comprising incorporating any fibers 11 and/or insulating particles    12 from a repulped insulated paper product 100 and/or a repulped    storage container 60 into a newly formed insulated paper product 100    and/or a newly formed storage container 60.

Adhesives and Paper Products Made Therefrom

-   112. An adhesive 40 suitable for bonding two or more paper layers 10    to one another, said adhesive 40 being at least partially filled    with one or more of the herein disclosed insulating materials 12.-   113. The adhesive 40 of embodiment 112, wherein said adhesive 40    comprises a starch adhesive 40.-   114. The adhesive 40 of embodiment 112 or 113, wherein said one or    more insulating materials 12 comprise perlite, perlite coated with    copper ions, expanded perlite, perlite hollow microspheres (such as    available from Richard. Baker Harrison Ltd., UK, or CenoStar    Corporation (US), perlite microspheres (such as Dicaperl HP-2000    sold by Dicalite), or Sil-Cell® microspherical perlite from    Silbrico, flaked or milled perlite (such as LD1006 sold by    Dicalite), porous volcanic materials (such as pumice), vermiculite    (including MicroLite® vermiculite dispersions, available from    Dicalite), hollow expanded vermiculite, glass foams, recycled glass    foams (such as manufactured by GrowStone Inc.), cenospheres (such as    available from CenoStar Corp.), glass bubbles (such as available    from 3M under the trade designation iM30K), silica aerogels (such as    those available from Aspen Aerogels, and those that may be    incorporated into paints and coatings under the Enova® and Lumira®    brand from Cabot), microporous polyolefin-based aerogels (such as    disclosed in US Patent Application Publication No. 2016/0272777 to    Aspen Aerogels Inc.), xerogels (i.e., collapsed aerogels), seagels    (i.e., microfoams made from agar and alginates), foamed starch,    foamed paper pulp, agar, foamed agar, alginates, foamed alginates,    bismuth oxychloride, metalized ceramics, metalized fibers, activated    carbon, cadmium yellow pigment (cadmium disulfide), or any    combination thereof.-   115. The adhesive 40 of any one of embodiments 112 to 114, wherein    said one or more insulating materials 12 are present in an amount    ranging from about 1.0 wt % to about 80 wt % of a total adhesive    weight comprising adhesive 40 and said one or more insulating    materials 12 and any other optional adhesive additives.-   116. A paper product (e.g., with or without insulating material 12)    comprising the adhesive 40 of any one of embodiments 112 to 115.-   117. An insulated paper product 100/100′ comprising the adhesive 40    of any one of embodiments 112 to 115.-   118. A corrugated paper product 100″ comprising the adhesive 40 of    any one of embodiments 112 to 115.

In addition, it should be understood that although the above-describedinsulated paper products and methods are described as “comprising” oneor more components or steps, the above-described insulated paperproducts and methods may “comprise,” “consists of,” or “consistessentially of” the above-described components or steps of the insulatedpaper products and methods. Consequently, where the present invention,or a portion thereof, has been described with an open-ended term such as“comprising,” it should be readily understood that (unless otherwisestated) the description of the present invention, or the portionthereof, should also be interpreted to describe the present invention,or a portion thereof, using; the terms “consisting essentially of” or“consisting of” or variations thereof as discussed below.

As used herein, the terms “comprises,” “comprising,” “includes,”“including,” “has,” “having,” “contains”, “containing,” “characterizedby” or any other variation thereof, are intended to encompass anon-exclusive inclusion, subject to any limitation explicitly indicatedotherwise, of the recited components. For example, an insulated paperproduct and/or method that “comprises” a list of elements (e.g.,components, layers or steps) is not necessarily limited to only thoseelements (or components or steps), but may include other elements (orcomponents or steps) not expressly listed or inherent to the insulatedpaper product and/or method.

As used herein, the transitional phrases “consists of” and “consistingof” exclude any element, step, or component not specified. For example,“consists of” or “consisting of” used in a claim would limit the claimto the components, materials or steps specifically recited in the claimexcept for impurities ordinarily associated therewith (i.e., impuritieswithin a given component). When the phrase “consists of” or “consistingof” appears in a clause of the body of a claim, rather than immediatelyfollowing the preamble, the phrase “consists of” or “consisting of”limits only the elements (or components or steps) set forth in thatclause; other elements (or components) are not excluded from the claimas a whole.

As used herein, the transitional phrases “consists essentially of” and“consisting essentially of” are used to define an insulated paperproduct and and/or a method that includes materials, steps, features,components, or elements, in addition to those literally disclosed,provided that these additional materials, steps, features, components,or elements do not materially affect the basic and novelcharacteristic(s) of the claimed invention. The term “consistingessentially of” occupies a middle ground between “comprising” and“consisting of”.

Further, it should be understood that the herein-described insulatedpaper products and/or methods may comprise, consist essentially of, orconsist of any of the herein-described components, layers and features,as shown in the figures with or without any feature(s) not shown in thefigures. In other words, in some embodiments, the insulated paperproducts of the present invention do not have any additional featuresother than those shown in the figures, and such additional features, notshown in the figures, are specifically excluded from the insulated paperproducts. In other embodiments, the insulated paper products of thepresent invention do have one or more additional features that are notshown in the figures.

The present invention is described above and further illustrated belowby way of examples, which are not to be construed in any way as imposinglimitations upon the scope of the invention. On the contrary, it is tobe clearly understood that resort may be had to various otherembodiments, modifications, and equivalents thereof which, after readingthe description herein, may suggest themselves to those skilled in theart without departing from the spirit of the present invention and/orthe scope of the appended claims.

EXAMPLES

Insulated paper products similar to exemplary insulated paper products100/100′/100″/60 shown and described in FIGS. 1-48 were prepared.

Example 1. Paper Containing Insulating Materials

Test Method:

Swatches of paper containing perlite were prepared and found to bethermally insulating. The insulating properties of the resultant paperswatches were assessed using two thermocouples attached to either sideof the sheet. The sheet was then placed on a hot plate and the rate ofheating of the face not in contact with the hotplate was recorded as therate of temperature rise (° C. per second per millimeter or Kelvin (K)per second per millimeter).

When added to cellulosic pulp at 10 wt %, 20 wt %, and 25 wt % and madeinto a swatch of paper, the heat-resistive properties allowed theperlite-infused paper to outperform the paper control and the papermixed with other compounds, and nearly as well as the polystyrene cups(0.0771 K/s·mm average heating rate for the polystyrene cups, with arange of 0.0825 to 0.1346 K/s·mm for the various perlite samples). Usinga statistical analysis test known as the F-test, it was confirmed with99.82% accuracy that the perlite-infused paper did indeed perform betterthan all other types of additives.

Materials Used:

-   Baking Soda-infused paper-   Chick-fil-A, McDonald's, and Sonic Expanded Polystyrene Cups-   Solo Cup-   #70 Wausau Crepe Paper (standard, with ridges, and double thickness)-   Additives:

Polylactic Acid 1.3 denier fiber Polyethylene Fybrel Polypropylene 1.5denier fiber Activated Carbon Sawdust Medium-Large Sized PerliteMedium-Small Sized Perlite MicrospheresEquipment Used:

Blender Paper-press box Hot plate Computer ThermocouplesProcedure to Make Paper:

1. Weigh out 3.36 g of the #70 crepe paper and pour into the blender.

2. Add 400 ml of water to the paper and blend the two until the mixturebecomes a pulp slurry.

3. Measure out the additives in the following quantities: 10% by weight(0.336 g), 20% by weight (0.672 g), and 25% by weight (0.840 g). Thesequantities are to prepare three different samples and would require therepetition of steps 1 and 2 for each amount.

4. Add the additive to the pulp slurry and mix the slurry with astirring rod.

5. Set up the paper-press box as follows:

-   -   a. Place the mesh screen over the white screen.    -   b. Place the wooden paper-box form over the mesh screen and        strap the box securely in place with the Velcro straps.    -   c. Place the wood block shaper into the paper-box form such that        it forms a 115 mm by 87 mm rectangle. It is shaped like a “T”        and should fit snuggly into place.

6. Pour the paper slurry evenly into the rectangular mold that wascreated.

7. There is a wooden block that should just fit into the rectangularmold. Cover one side of the block with wax paper and press down on thepaper slurry to remove the water.

8. Release the Velcro straps and remove the white screen, screen mesh,pressed pulp, wax paper, and wooden block as one unit.

9. Carefully remove the mesh screen from the pressed pulp.

10. Remove the pulp from wood block by carefully pulling the wax paperaway from the block.

11. Lay the wax paper and pulp on a flat surface and remove as muchwater by patting it with paper towels.

12. Allow the pulp paper to air dry before conducting heat transfertesting.

-   -   a. If time does not allow for the pulp paper to air-dry. Then a        heat source may be used to dry the paper. The heat source should        not exceed 65.6° C.    -   b. Remove the paper from the heat source when the paper is only        slightly damp.        Procedure to Test Rate of Warming of Surface Distant from the        Hot Plate:

1. Plug the data logger into the computer and open Wavescan 2.0.

2. Go to “Settings” and go through the following steps:

-   -   a. Click “Select Device” under “AI Selected Devices”.    -   b. The data logger should be the only option to be in the menu.        Click “OK”.    -   c. Click “Set Range” under “AI Channel Setting”.    -   d. Switch Channels 4 through 7 to “Thermo” on the top right of        the window and close out the window.    -   e. Set the “ChanStart” to 4 and “ChanCount” to 4 under “AI        Channel Setting”.    -   f. Change the “Interval” to 1000 ms.    -   g. Click “OK” at the bottom of the window.

3. Turn on “AI” under “Signal” near the bottom right of the window.

4. Check the box “AI Save2Disk” under “Device” near the bottom left ofthe window.

5. Verify that the room temperature is 21.5° C.±2° C.

6. Heat the hot plate within the temperature range of 37° C.±2° C.

7. Tape two thermocouples to each side of the paper sample and place thetest sample on the hot plate.

8.

9. Place a glass bowl on test sample such that the bowl is facing down.Make sure that the bottom thermocouple is in contact with the hot plateand the bowl does not cover the tip of the top thermocouple.

10. Click “Start” in WaveScan and allow the process to run for at least120 seconds.

11. Record the ambient room temperature for each test.

12. After the test has run, “Stop” the test and remove the sample andbowl from the hot plate.

13. Place the bowl into water at room temperature bowl down.

-   -   a. This helps to quickly cool the bowl to be reused for testing.    -   b. Be sure to thoroughly dry the bowl to remove another variable        heat sink from the experimentation.

14. Click “Save As” and save the file in the desired location.

15. Click on “History” and open “Project.wsp” in the file folder thatwas saved.

16. Click on “Convert” and save the file in the desired location.

17. Repeat steps 7 through 13 three times for each paper sample.

18. Testing each sample should take no more than 3 minutes.

Procedure to Process Data:

1. Open one of the data files with Excel.

2. Plot the data as Temperature versus Time for only the thermocoupleson the top of the paper sample. These data points can be distinguishedsince they will have lower temperature readings than the bottomthermocouples.

3. Add a trend line to both graphs of the two thermocouples and recordthe slopes of the trend lines. These values are the heat transfer ratesof the paper.

4. Do this for all three tests of each paper sample and take the averageof the heat transfer rate values.

5. Divide by the thickness in mm to get the thickness-adjusted values.

6. Repeat steps 1 through 4 for all paper samples.

Data:

The tables below categorize data for each sample containing 10% byweight of the different types of additives. Note: Thickness-adjustedvalues were obtained by dividing the average rate of heating by thethickness to eliminate the effect of variable sample thickness.

Heat Transfer Rate Testing of Different Insulating Materials 10% ByWeight Rate of Warming of Surface Furthest from the Hot Plate Average(Thickness Thickness Test 1 Test 2 Test 3 Adjusted) Sample mm (deg/s)(deg/s) (deg/s) (deg/s) (deg/s) (deg/s) (deg/s*mm) Cotton 1.65 0.21350.2134 0.2179 0.2179 0.2498 0.2498 0.1376 Activated Carbon 2.1 0.22990.2143 0.2016 0.1504 0.2051 0.2321 0.0979 Fybrel 1.52 0.2254 0.21930.3107 0.2919 0.1630 0.1764 0.1520 PLA 1.18 0.1787 0.1925 0.1531 0.15760.1726 0.1633 0.1437 Med-Sm Perlite 1.75 0.1934 0.1733 0.1152 0.10500.2803 0.2499 0.0941 Med-Lg Perlite 1.7 0.1872 0.1863 0.1207 0.11970.1202 0.1203 0.0837 Microspheres 1.18 0.1669 0.1690 0.1586 0.16060.2529 0.2430 0.1625 Polypropylene 2.6 0.1888 0.1883 0.2878 0.27730.3052 0.3062 0.1097 Sawdust 1.35 0.2218 0.2041 0.1878 0.1874 0.23040.2226 0.1548The table below categorizes the data points for each sample containing20% by weight of the different types of additives.

Heat Transfer Rate Testing of Different Insulating Materials 20% ByWeight Rate of Warming of Surface Furthest from the Hot Plate Average(Thickness Thickness Test 1 Test 2 Test 3 Adjusted) Sample mm (deg/s)(deg/s) (deg/s) (deg/s) (deg/s) (deg/s) (deg/s*mm) Activated Carbon 2.30.2099 0.1941 0.1763 0.1711 0.2316 0.2316 0.1088 Fybrel 1.57 0.28930.2844 0.3004 0.2876 0.1877 0.2001 0.1645 PLA 1.68 0.2322 0.2258 0.25630.2563 0.2131 0.2131 0.1385 Med-Sm Perlite 2.03 0.3365 0.3365 0.29480.3093 0.2328 0.2525 0.1346 Med-Lg Perlite 1.99 0.2328 0.2525 0.25790.2579 0.1577 0.1577 0.1102 Microspheres 1.21 0.1987 0.1955 0.25690.2570 0.3377 0.3377 0.1834 Polypropylene 1.45 0.2132 0.2235 0.19250.1804 0.1651 0.1611 0.1305 Sawdust 1.35 0.3022 0.3192 0.2916 0.27150.1841 0.1841 0.1917The table below categorizes the data points for each sample containing25% by weight of the different types of additives.

Heat Transfer Rate Testing of Different Insulating Materials 25% ByWeight Rate of Warming of Surface Furthest from the Hot Plate AverageThickness Test 1 Test 2 Test 3 (Thickness Sample mm (deg/s) (deg/s)(deg/s) (deg/s) (deg/s) (deg/s) Adjusted) Activated Carbon 2.33 0.21550.2155 0.1970 0.1833 0.2334 0.2215 0.0905 Fybrel 1.31 0.1922 0.18060.2094 0.1974 0.2093 0.1960 0.1507 PLA 1.45 0.2404 0.2320 0.2027 0.20910.1965 0.1899 0.1451 Med-Sm Perlite 2.5 0.2086 0.2086 0.2339 0.24460.1712 0.1712 0.0825 Med-Lg Perlite 2.3 0.2055 0.2055 0.2698 0.26750.2062 0.2027 0.0983 Microspheres 1.25 0.3524 0.3303 0.308 0.2904 0.19690.1837 0.1455 Polypropylene 1.57 0.1823 0.1802 0.2354 0.2425 0.24780.2491 0.1417 Sawdust 2.33 0.2425 0.2272 0.2459 0.2459 0.1817 0.17180.1195The table below categorizes the data points for each sample notcontaining a mixed-in additive.

Heat Transfer Rate Testing of Different Insulating Materials OtherMaterials Rate of Warming of Surface Furthest from the Hot Plate AverageThickness Test 1 Test 2 Test 3 (Thickness Sample mm (deg/s) (deg/s)(deg/s) (deg/s) (deg/s) (deg/s) Adjusted) Wausau #70 1.18 0.1640 0.20850.2681 0.2849 0.2317 0.2337 0.1964 Crepe Paper Wausau #70 3.48 0.20990.2000 0.1460 0.1460 0.2289 0.2289 0.0856 Crepe Paper w/Ridges Wausau#70 2.96 0.1585 0.1585 0.1567 0.1505 0.1834 0.1834 0.1520 Crepe PaperDouble Thickness Solo Cup 1.26 0.3434 0.3172 0.2734 0.2513 0.2577 0.28180.2281 McDonald′s 2.79 0.1729 0.1481 0.1334 0.1116 0.1313 0.1051 0.0479Fast-Food, Polystyrene Cup Sonic Fast-Food, 2.53 0.1833 0.1571 0.15490.1376 0.1498 0.1214 0.0595 Polystyrene Cup Chick Fil-A 2.08 0.28140.2814 0.2770 0.2867 0.2116 0.2114 0.1241 Fast-Food, Polystyrene CupPrym Paper 0.35 0.3418 0.3418 0.3716 0.3716 0.3119 0.3119 0.1976

FIG. 27 shows the most consistently effective materials at insulatingheat were the various polystyrene cups and the paper samples containingperlite. Nearly all of the perlite samples had better heat insulatingqualities than the Chick Fil-A cup, and the Med-Lg (10%) sample and theMed-Sm (25%) samples had comparable heat transfer rates to the mosteffective samples: the McDonald's and Sonic cups.

FIG. 28 graphically demonstrates that the paper samples with 10% perlitehad the most insulating properties relative to paper samples made withany of the other materials, as both perlite-containing paper sampleswith varying particle sizes had the smallest rate of heat transfer. Thismeans that the perlite samples retained the most heat, making them goodinsulators.

FIG. 29 graphically demonstrates that the paper samples with 20% perlitehad the most insulating properties relative to paper samples made withany of the other materials except the activated carbon, which performedslightly better than the perlite-containing paper samples in thisparticular test.

FIG. 30 graphically demonstrates that the paper samples with 25% perlitehad the most insulating properties relative to paper samples made withany of the other materials except for the paper samples made withactivated carbon, which again performed on par with theperlite-containing paper samples.

FIG. 31 graphically demonstrates that the polystyrene cups were the mosteffective insulators out of all the other non-additive materials. Inaddition, only the perlite samples were able to resist heat transfer aswell as the polystyrene cups (slightly worse than the McDonald's andSonic-sourced cups, slightly better than the Chick Fil-A sources cups).

FIG. 32 graphically shows the change in heat transfer rate with theaddition of more perlite with the medium/small grade. Note: To establisha trend of any mathematical significance, more data points would berequired (i.e., by creating more perlite/paper samples with variousweight percentages such as 5 wt %, 30 wt %, etc.).

FIG. 33 graphically shows how the effective heat transfer rate changeswith an increase in weight percentage of each grade of perlite.

Within each weight-percentage bracket, comparing the paper samples withperlite to those without shows clearly that the perlite adds anoticeable improvement to heat insulation properties. The pair ofperlite samples (one with a smaller particle size and one with thelarger) were, in all three weight percentages, always among the topthree most effective insulators. In comparison to the polystyrene cupssourced from various food vendors, the perlite samples generallyperformed on par with the polystyrene samples.

Conclusion: When added to a paper mixture, perlite dramaticallyincreases the paper's insulation properties (averaging a heat transferrate of 0.100 deg/s*mm), making it comparable to the industry standardexpanded polystyrene (averaging a heat transfer rate of 0.077 deg/s*mm).

These results suggested that paper-based materials with insulatingmaterials could be formulated to (i) provide highly thermally insulativecharacteristics, (ii) be able to be repulped, non-polluting, and (iii)be biodegradable and/or bio-destructable.

Example 2. Preparation of Insulated Paper Products

Test Methods:

% Solids Analysis:

A polystyrene disposable weigh boat was accurately weighed to 4 decimalplaces (tare mass). Approximately 1-2 gram of liquid was placed in theweigh boat, and promptly weighed to four decimal places (gross-wetmass.) Subtracting the tare from the gross-wet mass gives the net-wetmass. The weigh boat was carefully tilted and rocked from side to side,allowing the liquid to coat the bottom of the weigh boat evenly, then itwas placed in a cupboard for 24-48 hours to evaporate at roomtemperature. The dry weigh boat was re-weighed to four decimal places(gross-dry mass) Subtracting the tare from the gross-dry mass gives thenet-dry mass.% solids=100*net-dry/net-wetpH:

All pH measurements were made using universal indicator paper, assupplied by Micro Essential Laboratories Inc. The color of the paper andthe chart were compared under indoor fluorescent strip lighting.

Modified Lee's Disk Heat Transfer Rate Test Method

Lee's disk method is a known way to measure thermal conductivity in thinsheets with low conductivity. A modified version of the Lee's disk wasused to measure the heat transfer rate of samples generated, assembledusing available laboratory equipment, to enable a large number of teststo be conducted in a short period of time. Instead of allowing thematerials to reach thermal equilibrium, a digital hotplate was used tomaintain a set temperature for one side of the sample. The apparatus isdepicted in FIG. 34 (cross section) and FIG. 35 (exploded crosssection).

Materials/Equipment Used:

-   Paperboard sample(s)-   Circular cutting device set to cut 113 mm diameter circles (100 cm²)-   Calipers-   Scientific Balance, accurate to 0.001 g-   Digital hot plate 70 that heats to at least 37° C. (98.6° F.) and    with a heating surface 71 at least 113 mm in diameter-   10× Aluminum disks 72, 113 mm in diameter (100 cm²) and painted    matte black on one surface (McMaster 1610T37)-   Insulating hot plate guard 73, capable of withstanding temperatures    greater than 37° C. (93.6° F.) and constructed to fit the hot plate    70 and the sample stack being used (McMaster 93475K65)-   IR Camera 74 & Image Analysis Software (the Flir E-40 Thermal    Camera, available from Flir Systems Inc. Goleta Calif.)-   Timer    Assumptions:

This test method assumes constant heat flow, and no edge losses or othereffects from convection or radiation based heat transfer (all the heatflows through the disks and sample).

Method:

1. Cut 102 mm diameter circular paper samples and label appropriately.Ideally at least three samples can be cut from a single sheet. Fivesamples are recommended for each datapoint. Measure and record thethickness and weight of each sample using Vernier calipers.

2. Turn on the hot plate 70 and set the temperature to 37° C. Place theInsulating Guard 73 around the hot plate 70. Set one Aluminum disk 72 onthe hot plate 70, black side facing up. Once this disk 72 has reached37° C., sample testing can begin. The temperature can be checked byusing the IR camera 74.

3. While the hot plate 70 heats up, allow the other Aluminum disks 72 tosit out and come to room temperature. Measure the room temperature usingthe IR camera 74, and also use the IR camera 74 to confirm all theAluminum disks 72 have reached room temperature.

4. When ready to test, in quick succession:

-   Place the paper sample 10 on top of the hot plate aluminum disk 72-   Place a room temperature aluminum disk 72 on top of the paper sample    10, black side up-   Start a timer for 1 and 2 minutes

5. At the end of one minute, record the temperature of the top blackdisc 72 registering in the Flir thermal camera 74. After two minutes,once again record the temperature and take an IR image of the topsurface 75 of the aluminum disk 72. Remove the top aluminum disk 72 andpaper sample 10. Set aside to cool.

-   6. Repeat steps 4 & 5 until all samples 10 have been tested. If    running more than 9 tests, it must be ensured that the aluminum    disks 72 cool all the way to room temperature before being reused.

Representative warming curves are shown in FIG. 36. The best technicalway to approximate the thermal conductivity would be to monitor thetemperature rise of the aluminum disk 72 measured over time until thesystem reached a steady state. The ambient room temperature would haveto be taken into consideration too. To allow the inventors to undertakerapid screening, while compensating with variations in room temperature,a snapshot approach was chosen to record the temperature of the aluminumplate 72 via the Flir Thermal imaging camera 74. A first measurement wasmade immediately after placing the sample 10 and aluminum disk 72 ontothe pre-warmed hotplate (T₀) 70 and then every 30 seconds for the next 3mins 30 seconds. The temperature rise after 3 mins and 30 seconds wasrecorded in ° C. (T_(3.5)). The measurement was repeated, ideally 5times and an average taken.Delta T=T _(3.5 min) −T ₀

As the thickness of the sample also impacts the rate of heat transfer,the average thickness of the samples (d) was used to adjust the averagetemperature rise measurements over 3.5 mins. A “standard” thickness waschosen based upon a target material thickness (d_(std)). The averagetemperature rise was adjusted using the formula:Thickness Adjusted Delta T TADT=T _(3.5 min) −T ₀ *d/d _(std).The TADT is the heat transfer rate and is related to thermalconductivity in that the lower the TADT, then the lower the thermalconductivity of the sample.Thermal Emissivity Comparison Method #1 (Via Conduction):

A modified version of Leslie's cube was used to screen multiplematerials rapidly. The equipment is depicted in FIG. 37. FIG. 38 showsthe view from directly above the hotplate 70, viewing the sample 10 invisible light. FIG. 39 shows the thermal view using the Flir E40 thermalcamera 74.

One complication with this test is that it highly thermally insulatingmaterials will skew the results, as the method relies upon conduction ofheat from the back to reach the same temperature. So, if the flux ofheat traveling through is reduced significantly, then the black paintedarea will be cooling faster (through radiation) than sample area,leading to a slightly misleading result. For this reason, we developedseveral other tests to screen materials for emissivity.

Materials:

-   Paperboard sample(s) 10-   Rectangular corrugated strips, 1.5″×3″-   Calipers-   Digital hot plate 70 that heats to at least 37° C. (98.5° F.) and    with a heating surface 71 at least 113 mm in diameter-   IR Camera 74 & Image Analysis Software-   Timer-   Polished aluminum strip 76, 0.75 mm thick, 2″×3″-   Matte black spray paint (Rust-oleum High Performance Wheel, matte    black)-   3M Spray Adhesive    Assumptions:

This test method assumes constant heat flow, and no edge losses or othereffects from convection or radiation based heat transfer (all the heatflows through the sample).

Method:

1. Set the IR camera 74 to have an emissivity value of 0.95, or similar.

2. Turn on the hot plate 70 and set the temperature to 37° C. Once thehot plate 70 has reached 37° C., sample testing can begin. Thetemperature can be checked by using the IR camera 74.

3. Cut 1.5″×3″ cardboard strips. Spray them evenly with 3M aerosoladhesive.

4. Generously sprinkle the material 12 to be testing over the cardboard,then tap to remove the excess.

5. Mask one half of the cardboard with aluminum foil, then spray paintthe unmasked half of the sample with the matte black paint. Allow to dry(˜45 minutes).

6. Turn on the hot plate 70 and set the temperature to 37° C. Once thehot plate 70 has reached 37° C., sample testing can begin. Thetemperature can be checked by using the IR camera 74.

7. When ready to test:

-   Place the corrugated sample on top of the hot plate, painted side up-   Place the polished aluminum also on the hotplate as a control.-   Start a timer for 2 minutes

8. At the end of two minutes, take an IR image of the top surface 75 ofthe sample. Remove the cover plate and paper sample.

9. Repeat steps 6 & 7 until all samples have been tested.

Analysis:

Use the thermal images to compare whether the sample is more or lessemissive than the shiny or black painted portions.

The portion of the sample painted black has a high emissivity (approx.0.90), and thus shows up red and displays the correct temperature. Thepolished aluminum material has a low emissivity (approx. 0.03), and thusshows up blue and displays a lower temperature than the object actuallyis.

So for this test, one should be able to say whether the emissivity ofthe test sample is higher, lower, or roughly equal to the emissivity ofthe black or silver samples.

Thermal Emissivity Method #2 (By Illumination with an Incandescent LightBulb):

FIG. 40 shows the test apparatus used to quickly visually compare thethermal emissivity of materials directly from the way that they absorband then re-emit heat radiated from a hot-filament light bulb 83.Samples were mounted onto a shiny metal plate 82. Half of the sample wassprayed with mat black paint, and half was left exposed. All paint andadhesives used were allowed to dry at room temperature for at least 40minutes. The camera 74 was switched on, and the spotlight was shone ontothe samples from a low angle, so that stray heat radiation reflectedaway from the thermal camera 74. Immediately, black and high emissivitymaterials lit up in the thermal camera screen, as the absorbed heat andthen re-emitted it back out in all directions—including towards thethermal camera 74.

Materials with low emissivity were generally much darker in color, afterillumination for a few seconds.

Thermal Emissivity Method #3 Recommended by Flir Systems Inc.:

The following procedure was found it the Flir E40 manual, to give anactual emissivity number. Method #3 is as follows:

-   Step 1: Determine the reflected apparent temperature. This is needed    to compensate for reflected ambient radiation sources, reflecting    from your sample. Here are the steps:

i) Scrunch up a sheet of aluminum foil into a ball, and then uncrumpleit.

ii) Attach this to a sheet of card of the same size.

iii) Put the cardboard in front of the object to me measured, with thefoil pointing towards the camera 74.

iv) Set the internal camera emissivity setting to 1.0.

v) Record the apparent temperature of the aluminum foil

Step 2: Measuring the thermal emissivity:

vi) Adhere a strip of black electrical tape to the sample.

vii) Warm the sample up to at least 20° C. warmer than the ambienttemperature.

viii) With the camera 74 pointing to the tape, change the emissivitysetting to 0.97 and use one of the on-screen temperature measurementselection tools to measure the temperature of the tape.

ix) Move the temperature measurement tool to the sample surface withoutthe tape. Now, change the internal emissivity setting until the measuredtemperature matches that of the insulating tape.

x) Record the emissivity of the sample.

Thermal Emissivity Test Method #4:

Thermal emissivity of certain samples was also tested by ThermophysicalProperties Research Laboratory, Inc. of West Fayetteville Ind. using thefollowing test methodology.

The Table Top Emissimetry apparatus measures total normal emissivityover a broad wavelength band. Thin, square samples, 0.5″ on a side aremourned facing downward on an isothermal copper block heated by aresistance heater and surrounded by ceramic insulation. Five type-Kthermocouples are mounted on the bottom face of the isothermal plate.Sample temperatures during emissivity measurements are inferred from theclosest thermocouple. The samples are exposed to ambient air withconvection losses minimized by the face-down orientation of the samplesand the small gap to the detector head.

The IR detector is a broadband thermopile with a 1 mm diameter sensitivearea and flat spectral response from 1-40 micrometers. The detector andradiation shield are water cooled and view the sample through a 3.56 mmaperture 5 mm from the sample surface. The detector is sensitive toradiation from an approximately 4.57 mm diameter spot on the sample.Stray radiation on the detector is minimized by a flat optical blackcoating on the inner surface of the shield and both faces of theaperture plate and by cooling the shield and aperture plates. The shieldtemperature is monitored by two type-K thermocouples embedded in theshield walls. Thermocouple and detector voltages are fed to a A/D moduleand attached to a personal computer. The emissivity c is calculated bythe equation:

$\epsilon = {\frac{{\epsilon_{shutt}( {T_{shutter}^{4} - T_{shiel}^{4}} )} + {S\;{\epsilon_{blkbody}( {T_{blkbody}^{4} - T_{shie}^{4}} )}}}{( {1 + S} )( {T_{sample}^{4} - T_{sensor}^{4}} )}\mspace{14mu}{where}\text{:}}$$S = \frac{( {V_{sensor} - V_{shutter}} )}{( {V_{blkbody} - V_{sensor}} )}$and V is the detector voltage, T is the temperature measured in Kelvin.The subscripts are as follows:

T_(shutter) is the temperature of the shutter.

T_(shield) is the temperature of the infrared detector when the shutteris in place.

T_(sensor) is the temperature of the infrared detector duringmeasurements.

T_(blackbody) is the temperature of the standard blackbody used tocalculate the unknown values.

T_(sample) is the temperature of the sample using the thermocouplenearest the sample.

V_(shutter) is the voltage from the infrared detector when the shutteris in place.

V_(blackbody) is the voltage from the two black body readings taken.

V_(sensor) is the voltage of the infrared detector from each sample.

∈_(shutt) is the emissivity of the shutter at the temperature when read(∈=0.09)

∈_(blkbody) is the emissivity of the blackbody standard (∈=0.95)

∈ is the emissivity of sample.

In operation, power to the heater is adjusted by a computer controlledEurotherm temperature controller to achieve a desired plate temperatureand the system is allowed to stabilize. The detector is aligned with thesample to be viewed and its output voltage recorded. All samples on theisothermal plate are maintained in a constant radiation and convectiveheat transfer environment as the X-Y table is moved by the extendedinsulation block surrounding the detector head. Measurement of anoxidized copper reference standard with ∈=0.96±0.01 and a closedaperture measurement are made before and after each sample suite at eachtemperature. Total hemispherical emissivity is estimated from totalnormal/total hemispherical relationships developed for metals andinsulators. The current temperature range covered is from roomtemperature to around 150° C.

Expanded Polystyrene Cooler Window Test Method

This test was devised to measure the amount of heat flowing through agiven sample, as if it were placed in direct sunlight on a hot day.While a steady-state test would be ideal, the inventors sought methodsto make rapid assessments of thermal properties for further research.While not wishing to be limited by theory, this test combines bothemissivity (absorption of radiative heat) and conduction to give ameasure of the amount of heat passing through a given sample.

Approximately 5 US gallons of Atlanta city water was placed into a 6gallon bucket and sealed with a lid to equilibrate to room temperaturefor at least 24 hours. Expanded polystyrene coolers 290 were purchasedfrom Uline (Pleasant Prairie Wis.) (part number S21529), insidedimensions: 8″×6″×7″, wall thickness 1.5″, and outside dimensions11″×9″×10″. A 100 mm diameter acrylic circular template was used to drawa circle 291 on one of the 11″×9″ faces 292 of the cooler 290. Thecircle 291 was positioned 60 mm from the top 293 of the cooler 290, and88 mm from either side 294/294, as shown in FIG. 43A-43B. The circle 291was carefully cut out using an electrically heated hot knife (e.g.RoMech Pro Hot Knife Kit 200 W Styrofoam cutter, made in China).

Two part liquid silicone compound was mixed and used to seal the insideof the insulated cooler 290 by painting the inner surfaces 295. Thesilicone resin (for example, Diamond Driven Liquid. Silicone Compound,available from Amazon.com, or Oomoo 30 Silicone Mold. Making Rubberavailable from Amazon.com, or Smooth-On Ecoflex 00-35 fast platinum curesilicone rubber compound kit, available from Smooth-On throughAmazon.com, or RTV Silicone Rubber for Mold Making available fromSpecialty Resin & Chemical LLC, Dowagiac Mich., or similar) was allowedto cure overnight. The following day, excess silicone resin was cut fromthe exterior of the cooler 290 in the vicinity of the cut circular hole291, to ensure bondability between the expanded polystyrene and thesample. Although silicone resins were used, it was also found that epoxyresins could alternately be used to waterproof seal coolers 290 withoutdestroying the expanded polystyrene structure.

Sample preparation: Coatings were made onto 35 lb per 1000 sq ft (35 MSQor 170 gsm) kraft board using meyer rods and dried. Example board isavailable from Juvo Plus Inc. (Irwindale Calif.) in the form of “200pack kraft laser and ink jet printer post cards 2 up per page” SKULJ-WACHG-031218-11-1. This paper was selected as it proved to be a moreconsistent source of kraft fiberboard than obtaining samples of 35 lbMSQ liner board from various corrugated board manufacturers. In sometests, the kraft fiberboard was substituted with a sheet of papercontaining fillers, or thermal insulation elements or other materialsthat the inventors wished to assess, such as metallized bubble wrap.

Aluminum foil (e.g. Glad® Heavy Duty Aluminum Foil, distributed byPhoenix Industries Inc Denver Colo., and available in grocery stores)was cut into sheets which were sprayed black on the dull side, usingmatt black spray paint (e.g. Rust-Oleum® Painter's Touch 2× UltracoverPaint+Primer, Rust-Oleum Corporation, Vernon Hills Ill.) and allowed todry. The acrylic 100 mm diameter template was then used to mark and cutcircular samples of coated kraft board. The back (kraft paper) sides ofthese were then sprayed with an adhesive such as 31M® Super 77™Multipurpose Adhesive, made by 3M Company (Minneapolis Minn.) and soldin many craft, office, and hardware stores. The discs were carefullybonded to the shiny side of the painted foil, and placed between papersheets under several books (about 1 kg pressure) until dry, to maintainflatness of the sample. The foil sheet was trimmed so that approximately0.5″ to 1″ of shiny foil remained surround the each sample.

3M® Marine Adhesive Sealant Fast Cure 4000 UV (part #05280) was thenused to carefully adhere the black surface of the foil-sample compositeto the outside of the cooler 290, so that the sample was in line withthe opening 291 into the cooler 290. Other sealants could be usedprovided that they bond to both painted foil and expanded polystyrene,do not destroy expanded polystyrene by partially dissolving it, and thatthey form a waterproof seal. This was then allowed to cure overnight.

The cooler 290 with the sample window was placed on the test rig 296built and illustrated in FIG. 43B. The test rig 296 allows therepeatable location of the test window in front of the 110V 250 Wtungsten filament heat lamp 297 such as those used in restaurants tokeep prepared food hot prior to serving (e.g. Intertek 5000707, whiteincandescent tungsten heat lamp). The test rig 296 shown in FIG. 43Bincludes adjustment of angle of incidence and distance from the surface298 of the lamp 297 to the center 299 of the test material 300. 4,500 gof water that had been allowed to equilibrate to room temperature wasweighed to the nearest gram (using a Philips® Essence kitchen electronictop pan scale 1 g increments to 5 kg capacity) and poured into thecooler 290. The stirrer blade 301 was inserted through the lid 302, anda digital thermometer probe 303 was also inserted through the lid 302. Astrobe light (not shown) was used to time the rotation of the stir blade301 to 600 rpm.

The water was stirred for several minutes until the temperaturestabilized, at which time it was recorded. A timer was set for 15minutes. The heat lamp 297 was switched on, and the timer (not shown)started simultaneously. The temperature of the water in the cooler 290was recorded every 15 minutes for one hour.

All tests were conducted in an air conditioned temperature controlledenvironment with an air temperature between 68° F. and 71° F. Positivecontrol sample was a kraft disk that also had a layer of aluminum foillaminated to it before adhering it to the shiny side of black paintedfoil, and a negative control consisted of an uncoated kraft disk mountedonto a similar foil sheet. The temperature rise (DT) over one hour wasused to determine the amount of energy (Joules) flowing through thecoated kraft board 300 per unit time (Watts) using the equation:E(Joules)=4.2*DT*4500where 4.2 is the specific heat capacity of water in J·K⁻¹·g⁻¹; and 4500is the mass of the water present in the container. Rate of energytransfer into the water Watts (ER) through the window 291 is calculatedby dividing by the number of seconds in one hour, viz.:ER=E/3600 WattsAs the surface area of the disc 300 is known, then the energy flux Wattsper square meter can also be calculated (W·m²)

In some experiments, an infrared thermometer (Etekcity Lasergrip 1025 D)(not shown) vas also used to measure the outside temperature of the disk300, to give an approximation of the temperature difference over thethickness of the sample.

Cardboard Corrugated Box Performance Testing:

The five specifications listed below for each of cool and frozen foodare desired criteria for a successful product.

Cool Food performance: Compliant with ISTA test TNPK-001 using “Heat”profile, which in summary is as follows:

23° C./734° F. Ambient temperature

Box is 12″×10″×7″

Product: 900 g 2 lbs of Cooked Pork (or simulant)—packed at 2° C./35.6°F.,

1800 g/4 lbs of Gel Paks: 1 lb each, conditioned to −20° C./−4° F.

Temperature of the product remains below 8° C./46.4° F. after 10 hoursat ambient.

Frozen Food performance: Compliant with a modified ISTA test TNPK-001using “Heat” profile, which in summary is as follows:

23° C./73.4° F. Ambient temperature

Box is 12″×10″×7″

Product: 900 g/2 lbs Frozen cooked pork (or simulant), conditioned to−20° C./−4° F.

Gel Paks: 1800 g/4 lbs of gel packs (1# each), conditioned to −20°C./−4° F.

Temperature of the product remains below 0° C./32° F. after 10 hours atambient.

% Ash Content:

These tests were carried out by SGS Integrated Paper Services Inc.,Appleton Wis. according to TAPPI T 211 om-16 Ash in wood, pulp, paperand paperboard: combustion at 525° C. Approximately 10.0 g of paper wasaccurately weighed, and then ached in a muffle furnace at 525° C. Theremaining ash was then re-weighed to determine ash content.

% Moisture:

These tests were carried out by SGS Integrated Paper Services Inc.,Appleton Wis. according to TAPPI T 550 om-13 Determination ofequilibrium moisture in pulp, paper and paperboard.

Repulpability:

Repulpability was tested by SGS Integrated Paper Services Inc., AppletonWis. according to the “Voluntary Standard for Repulping and RecyclingCorrugated Fiberboard treated to Improve It's Performance in thePresence of Water and Water Vapor Protocol of 2013”, generated by theFiber Box Association, headquartered in Elk Grove Village, Ill., 60007.Repulpable means the test material that can undergo the operation ofre-wetting and fiberizing for subsequent sheet formation, using theprocess defined in this standard. In the repulpability test, materialsare weighed, pulped in a specific manner using laboratory equipment, runthrough a laboratory disintegrator, and then run through a screen. Theamount of rejected material is compared to the material that could bereused as pulp to make board as a % by mass. Two figures are derived:The first is the acceptable recovery of the fiber based upon the mass ofmaterial first entered into the test, and the second is the percentageof the recovered fiber that is accepted, not rejected. These figuresconstitute the “% re-pulpability”, and the fiber box association hasdetermined that a pass for both measures of repulpability is >85%. Otherparameters recorded are: a) material fouling the equipment duringpulping or forming b) material that does not disintegrate and has to beremoved (becomes part of the rejects)

Adhesive Bonding/Pin Adhesion and Ply Separation Test:

This is an important test to ensure the strength of the bonds betweenthe flutes and the liner board, which in turn relates to the integrityand strength of the box structure. A jig is used, with pins that fitbetween the corrugated flutes. The stress force needed to separate thelayers of the corrugated card is measured. The Fiber Box Association hasseveral tests for this bond strength.

Pulp Preparation Method—from 35# Unbleached Liner Board:

Unbleached 35-lb liner board (available from International Paper) wascut into 8.5″×11″ sheets. These were then cut in half, making 8.5″×5.5″sheets, weighing approximately 5.35 g. These were fed through an officecross-cut shredder and placed into a 1 quart mason jar (Ball). Boilingwater was poured over the shredded paper (approximately 800 ml) and thiswas left to soak for at least 10 minutes. The paper wetted out, asevidenced by it changing to a darker brown and sinking to the bottom ofthe jar.

The wetted out shredded paper was placed into a kitchen blender(Black+Decker, 10 speed, model number BL2010BPA) and blended at thehighest speed. Blending took around 2-4 minutes, until the pulp appearedto me homogeneous, and poured without back into the jar without lumps.

If other materials, such as insulating elements are to be added to thefinished pulp, it is done so as follows. The mason jar of pulp wasopened. A laboratory mixer blade was lowered into the jar and a variablefrequency drive was used to run the stirrer motor to give a controlledstirring. Additives were added to the pulp jar. After the final materialwas added, the pulp was further stirred for an additional 5 minutes.

Pulp Preparation Method—From Bleached Recycle Pulp:

Grade 100 bleached pulp secondary fiber was supplied by Donco RecyclingSolutions (with offices in Chicago Ill.) This pulp containedapproximately 50% solids and 50% water. The fiber content was a blend ofpre- and post-consumer fiber, sourced from PE-lined milk cartons, aswell as pre-consumer paper scrap and pre-consumer PE-Lined paperboardcarton material. The target specification for the pulp fiber was asfollows: 9.050 g+/−0.050 g was placed into a 1 quart mason jar (Ball).City water was poured over the pulp (approximately 800 ml) and this wasthen poured into a kitchen blender (Black+Decker, 10 speed, model numberBL2010BPA) and blended at the highest speed for 1 minute.

If other materials, such as insulating elements are to be added to thefinished pulp, it is done so as follows. The mason jar of pulp wasopened. A laboratory mixer blade was lowered into the jar and a variablefrequency drive was used to nm the stirrer motor to give a controlledstirring. Additives were added to the pulp jar. After the final materialwas added, the pulp was further stirred for an additional 5 minutes.

Handsheet Paper Formation Method:

As shown in FIG. 41, a mesh screen 95 was held taught and mounted onto asquare wooden frame 96 using staples 97. A second wooden frame 98 around4″ tall attached on top of the mesh screen layer 95, via hook-and-loopVelcro® straps 99. A large tub was partially filled to around 4″ depthwith water, and the screen 95 strapped to the frame 96/98 was submersedinto the tub. The inside of the frame 96/98 now contained water.

The fresh pulp formulation was poured into the center of the frame96/98, and the furnish was “hogged”. Hogging is a process whereby thehand is lowered into the frame, while it is still filled with water andpulp, and agitated near the top of the screen. This helps ensure evendistribution of fiber in the hand sheets.

The frame 96/98 including the attached screen 95 was removed from thetub and held level to even allow drainage and distribution of thefibers. This process is known to paper crafters as “pulling”. Pulling isanalogous to the wet end process shown in FIG. 8A. Once no liquid wasvisible, the assembly was tilted to allow residual water trapped betweenthe screen frame 96/98 and the box frame to also escape, otherwise itmay flow back over the new paper sheet forming, and destroy the evensurface. The pulp, still containing much moisture, is now ready for“couching”.

In a separate shallow tub (not shown), layers of thick non-woven PETfelt were wetted and stacked. Additional wetted felt sheets wereavailable to place on top of the newly formed sheet. The larger boxframe 96/98 was removed from the screen holding the partially formedpaper. In one smooth rolling motion, the screen frame was inverted,pressed onto the top layer of wet felt, and the screen lifted off,leaving the pulp behind on the felt. This process is known to papercrafters as couching. In a production environment, it is analogous tothe felt press process of FIG. 8B.

For two or more ply samples, the process was repeated, pulling andcouching more layers of partially formed paper to build the paper sheetin layers. Once the desired sheet thickness was reached, after couchingthe last layer, a small paper label was placed in the corner,identifying the sheet sample ID, and a second sheet of moist felt wasplaced on top of the paper sheet. The next sheet for the next sample wasthen couched on top of the pile of nonwoven and paper, to form a stack.

The stack of papers was placed in a press. A hydraulic jack was used toapply pressure, expressing water from the stack. This process isanalogous to further felt presses on the production line (FIG. 8B). Thestack of pressed paper was separated, with each sample sheet placedbetween two felt sheets. Each of these sandwiches were stacked betweensheets of corrugated card. The flute direction of the corrugated sheetswas aligned in one direction in the stack, allowing air movement throughthe stack. The stack was weighed with 10 lbs of weight, placed in frontof a box fan, and left to dry for 24-48 hours at ambient temperature.

Coating Method:

A clip attached to a ¾″ thick glass plate is used to hold a stack ofphotocopy paper and the sheet of paper to be coated. A strip of maskingtape was placed along the top of the sheet to be coated, and a papertowel was left hanging off the end. A transfer pipette was used to makea line of coating on the masking tape. This prevented the coating fromprematurely soaking into the paper board to be coated. Meyer rods(available from RD Specialties Inc.) were used to draw the coating downover the sheet. The coating was then dried under ambient conditions.

Wetting Out and Stabilization:

Before materials can be included in a coating or into the fibrous matrixof paper, materials first have to be wetted out and dispersed. Somematerials such as glass have high enough surface free energy that thewet out spontaneously whereas materials such as perlite and aerogelrequire surfactants to lower the surface free energy of the water enoughto wet out the material.

Surfactants may be non-ionic, cationic, or anionic. They may be highmolecular weight polymers or copolymers, or they may be low molecularweight, and able to reach newly created interfaces rapidly. Surfactantsfor aqueous systems may be characterized by their HLB value. HLB standsfor Hydrophilic-Lipophilic Balance, and is a measure of the capabilityof the particular surfactant to wet out various surfaces of differingsurface free energy. Very hydrophobic materials have a low surface freeenergy, so a matching surfactant should also have a low HLB value. Morehydrophilic surfaces—those with multiple polar groups perhaps, requiresurfactants with higher HLB values.

Microspersion EZ manufactured by Micropowders Inc. of Tarrytown N.J. isa non-ionic low molecular weight surfactant with a low HLB. Dawn® liquiddish soap, manufactured by the Procter & Gamble Co (Cincinnati Ohio) isan example of a low molecular weight anionic surfactant. E-Sperse 100(from Ethos, Greenville S.C.), Triton BG-10 (Dow) Glucopon 425 N (BASF)and Glucopon 215 UP (BASF) are additional materials that can wet outcertain hydrophobic materials. The Surfynol® range available from Evonikare ethoxylated acetylenic diols of fairly low molecular weight. Theyare non-ionic, and low foaming due to the molecular interactions of theacetylenic moiety with the water surface. Surfynol 104, 440, 420 arerepresentative examples.

Higher molecular weight materials are useful for stabilizing dispersionsof various materials in water. Polymers may be anionic, cationic, ornon-ionic or have a mixture of characteristics. Polymeric dispersants,also known as “grid aids” are often co-polymeric in nature, for instancesome of the Joncryl resins from BASF are believed to be methacrylicacid-styrene-butylmethacrylate copolymers, containing anionic ionizablegroups. Zetasperse 3100, Zetasperse 3800, TegoDispers 752W, andTegoDispers 755W are also higher molecular weight dispersing agents witha net negative formal charge when ionized available from Evonik.Disperbyk 190, as well as other Disperbyk products available from BYKChemie (Wallingford Conn.) are also polymeric/copolymeric materials thathelp stabilize dispersions through a) increasing particle surfacenegative charge (electrokinetic stabilization), and b) by allowingsteric stabilization by dint of segments of polymer dissolving into thecontinuous medium.

Insulation Element Density:

The insulating elements used to mitigate conductive heat transfer arevery low in density. 1 g of Innova aerogel powder occupies around 7 cm³of volume. The perlite microspheres and milled and classified perliteflake are of similarly low density, in the range of 100-200 kg·m⁻³. Ifwe assume that the density of paper fiber is approximately 1 g·cm⁻³,then the following is approximately true regarding the % by volume:

% Perlite by mass: Approximate % Perlite by volume: 66.7%  93% 50% 88%30% 75% 25% 70% 20% 64% 15% 55% 10% 44%  5% 27%Formulations Containing Starch Adhesive:

Corn starch adhesive (approximately 25% solids) is applied to the top ofthe media board flutes in order to laminate with the linerboard, makingcorrugated cardboard. The corn starch is modified with the addition of asmall quantity of sodium hydroxide and sodium borate (less than 1% ofthe solids.) These additions reduce the gel-point of the adhesive fromaround 185° F. to 145° F. Part of the starch contained in the adhesiveis in true solution (referred to as “cooked starch”, while additionalstarch is added without cooking to form swollen starch gels. At thepoint of corrugation, the high temperature of the corrugator heats thegels, dissolving them, and boosting viscosity as the adhesive bonds withthe paper fibers. If strength is needed under moist conditions, anadditional resin may be added referred to as Moisture Resistant Additive(MRA), to impart moisture condensation resistance. For instance, if abox is stored in a freezer, then moved into a room temperatureenvironment, then it's likely that the box will “sweat” as water vaporcondenses on the surface of the cold box. Such MRA resins includeCoragum SR available from Ingredion in WestChester Ill., and istypically added at 1%-1.5% to impart moisture resistance.

The inventors realized that the physical contact between the corrugatedflutes and the liner board presented opportunities for conductive heattransfer. For this reason, the inventors investigated increasing thethermal insulating properties of the starch adhesive.

Modified starch mixed adhesive mixture was warmed, thoroughly mixed andthe solids content measured at 29.7%. It was used to make the followingcoatings, 16-01 to 22-02. 22-02 had to be put into a blender for 8minutes in order to make an acceptable coating.

Paint base is sold in paint supply stores prior to adding pigment tomake customized colors. Deep color paint base contains little in the wayof pigments, and mostly only binder, viscosity control agents, and amineral extender such as calcium carbonate. Behr Pro 23 Deep Base,available from The Home Depot retail store was tested for solidscontent: 53.6% solids. This paint base was used as a binder to make morecoatings containing insulating elements, JL 30-01 to JL 39-01.

Formulation Amount per No. Formulation Contents Substance (g) JL 16-01Cornstarch Adhesive as supplied 150.00 Control JL 16-02 Microspersion EZ(neat) 0.15 Cornstarch Adhesive (wanned to 100.00 400 C.) Perlite 20 um10.00 JL 19-01 Perlite 20 um 30.01 Microspersion EZ (neat) 0.37Cornstarch Adhesive (wanned to 170.00 400 C.) JL 19-03 3M Glass BubblesiM30k 18.00 Microspersion EZ (neat) 0.30 Cornstarch Adhesive 182.00 JL20-02 3M Glass Bubbles iM30k 40.80 Microspersion EZ (neat) 0.30Cornstarch Adhesive 163.20 JL 22-02 Aerogel IC 3120 18.00 MicrospersionEZ (neat) 0.34 Starch Adhesive 182.00 Blended for 8 minutes Coatingformulations based upon paint base. JL 30-01 Behr Deep Base 40.00 Water40.00 3M Glass Bubbles 40.00 JL 30-02 Behr Deep Base 60.00 Control Water60.00 JL 30-03 Behr Deep Base 50.00 Water 50.00 3M Glass Bubbles 8.83 JL31-02 Behr Deep Base 50.00 Water 85.00 3M Glass Bubbles 80.40 JL 34-01Behr Deep Base 100.00 Water 175.00 Aerogel Enova IC 3120 35.29 JL 35-01Behr Deep Base 100.00 Water 100.00 Aerogel Enova IC 3120 19.78 JL 35-02Behr Deep Base 100.00 Water 100.00 Aerogel Enova IC 3120 19.78 JL 39-01Behr Deep Base 50.00 Water 50.00 Thermacell 25.00Low Emissivity Insulative Clay Coatings:

Many corrugated cardboard boxes and fiberboard packages are coated witha clay coating. This coating provides a smooth flat ink-receptivesurface that allows high quality printing, it covers the brown color ofunbleached pulp with white, and gives the packaging a higher qualityfeel. Often the coating is applied in two layers. The first layer iskaolin clay based, whitened by calcium carbonate. This layer helpssmooth the surface by filling in low spots. The second layer alsocontains titanium dioxide and calcium carbonate. The formulations ofclay coatings vary. Usually, they contain kaolin clay, along with a filmforming binder, such as an acrylic latex, or sometimes a cornstarch. Apolymeric dispersant is usually included to stabilize the clay coating,and a viscosity control agent is usually also included, such ascarboxymethyl cellulose, or an hydrophobically associated alkaliswellable polymer (HASE polymer.) Calcium carbonate is also usuallyincluded, along with titanium dioxide pigment for whitening. The claycoating offers another opportunity to incorporate insulative elementsthat reduce conduction and radiative heat transfer.

Emissivity Screening Results of Materials—Conductivity Method:

Powdered materials were sampled and tested to observe emissivitydifferences through a thermal camera. The emissivity of the powdersurface and the powder surface sprayed with black paint were compared.NVD=no visible difference.

Comment after 2 minutes Material of heating Aerogel IC 3120 powderPossible lower emissivity Perlite P-32 75 micron (cenosphere) NVDThermacel powder Possible lower emissivity Hi Refractive Index glassbeads 60μ Possible lower emissivity Hi Refr. Index glass beads 35μ-45μNVD Hi Refr. Index glass beads 180μ-600μ NVD Titanium dioxide powderLower Zinc oxide powder NVD Yellow oxide pigment (iron oxide) NVDBismuth oxychloride powder Lower Party pink mica powder NVD Super pearlywhite mica powder NVD Snowflake sparkle mica powder Lower Queens purplemica powder NVD Diatomaceous Earth powder NVD Mica Sheet Lower KaolinClay powder NVD Silicon powder Lower Kaolin Coating - 42-02 Lower(slight) Diatomaceous earth coating 43-01 Lower (slight)

These powder sample data gave us several ideas for follow up tests.Curiously, some of the materials gave different results if they arefirst formulated into a coating (e.g. kaolin and diatomaceous earth). Inother cases, low thermal conductivity may have skewed some readings.

Emissivity Screening Results of Materials—Illumination Method:

Both powdered materials, as well as materials incorporated into coatingscoated onto fiberboard were sampled and tested to observe emissivitydifferences through a thermal camera. The emissivity of the powdersurface/coating surface and regular Cardboard were compared whenilluminated by an incandescent tungsten spot light. NVD=no visibledifference in emissivity vs. cardboard. Coating formulas follow below.NT=not tested

Comment 4 seconds Material of illumination Aerogel IC 3120 powder NVDSilicon powder NVD Snowflake Sparkle Mica Lower Pewter Silver mica NVDHi RI glass beads 60μ Al coated NVD Hi Refr. Index glass beads 35μ-45μSlightly lower Thermacels NVD Titanium dioxide Lower Zinc oxide LowerMica Sheet Much Lower Bismuth oxychloride powder Much Lower Perlite P-32(75μ) NVD 30-03, Meyer #130 (25% glass bubbles) Slightly lower 22-02,Meyer#130, (24% Aerogel in starch) Lower 19-01, Meyer#130, (37% Perlitein starch) Much Lower 19-01, Meyer #40, (37% Perlite in starch) LowerKaolin Powder Slightly Lower Kaolin Coating - 42-02 Meyer #40 Much LowerDiatomaceous Earth powder Lower Diatomaceous earth coating 43-01 NVDAerogel Coating 38-02 (~50% aerogel) Much Lower Bismuth Vanadate MuchLower BiLite 20 Much Lower Gypsum Lower Sericite Pigment Lower AluminumOxide Powder Lower

These data gave us additional ideas to pursue insulating against thermalradiative emission and absorption, in addition to insulating againstthermal conduction.

Additional Material Sources:

Glass beads, including high refractive index glass, and retroreflectivehemi-spherically mirrored glass beads—Cole Safety Products,

Glass microbubbles—3M specialty materials, iM30K

Bismuth oxychloride—Making Cosmetics Inc (Redmond Wash.). This is apearlescent pigment, commonly used in cosmetics and packaging to imparta pearl effect. Other sources include BASF, as Biju Ultra UFC and PearlGlo.

BiLite 20 powder—BiOCl coated onto mica flakes (BASF)

Bismuth Vanadate—Dominion Colour, Ontario

Titanium Dioxide—Brambleberry (Bellingham, Wash.)

Zinc Oxide—Brambleberry (Bellingham, Wash.), and Sky Organics

Snowflake Sparkle Mica—Brambleberry (Bellingham, Wash.)

Super Pearly White Mica—Brambleberry (Bellingham, Wash.)

Pewter Mica—Brambleberry (Bellingham, Wash.)

Party Pink Mica—Brambleberry (Bellingham, Wash.)

Queens Purple Mica—Brambleberry (Bellingham, Wash.)

Yellow iron oxide powder—Brambleberry (Bellingham, Wash.)

Thermacels—HyTech Thermal Solutions, Melbourne Fla. This material is anadditive that is advertised to be mixed into paint in order to increasethe paint's insulating properties.

Rhoplex VSR-50 is an acrylic low VOC film forming binder emulsion inwater. Commonly used in architectural coatings. Originally sold by Rohm& Haas, now available from Dow Chemical.

Sericite comprised sericite mica surface treated with magnesiummyristate or Sericite White sparkle luxury mica colorant pigment powderby H&B Oils Center Co.

Supertherm paint, from Eagle Specialty Coatings, British Columbia,Canada

Coatings to Test for Emissivity on Fiberboard or Card

Formulation ID Materials Quantity/g JL 48-01 CaCO₃ 50.00 Water 50.00 10%Rhoplex VSR-50 in water 20.00 JL 48-02 Kaolin Clay 50.00 Water 70.00 10%Rhoplex VSR-50 20.00 JL 48-03 Bismuth Oxychloride 20.13 water 33.55 10%Rhoplex VSR-50 in water 8.05 HT 50-01 Eagle Specialized CoatingLow Emissivity Coatings on Fiberboard—Cooler Window Tests

Based upon the rapid testing using tests 1 & 2, several materials wereselected for further investigation. In preparation for printing,fiberboard is often coated with a clay coating, which smooths thesurface and gives it a white color. A simple clay coat formulation wasgenerated:

Kaolin Clay Coating 127-01:

Material Quantity (g) Water 130 Tego Dispers 755W 4.86 Evonik Rovene6400 52.89 Mallard Creek Polymers Hydrite SB60 157.8 ImerysLow Emissivity Coating Formulations by % Composition

% TS110 137-02 TS111 TS112 TS113 137-06 127-02 137-04 137-05 136-01Water 62.5 68.15 64.28 65.51 65.51 65.51 65.51 17.5 30.48 65.55 T-755W8.18 2.5 5.01 5.10 5.10 5.1 5.1 5.1 R-6400 2.75 R-4100 2.85 2.71 2.852.85 2.85 2.85 2.85 2.85 2.85 HPMC 1.96 BiOCl 26.56 BiLite 26.5 ZnO26.04 ZnS 26.54 MgO 26.54 TiO₂ 26.5 Al-ZnO 26.54 TH1000 80 TH500EF 66.67Ag-Glass bubbles 26.5 ZnO-Sky Organics HPMC-3% aq solution ofhydroxypropyl methyl cellulose. BiOCl-Bismuth oxychloride, sold as PearlGlo (BASF) Al-ZnO-Aluminum-doped zinc oxide semiconductor, AZO 100,20-40 nm particle size, available from Oocap Inc. Las Crusas NM. TH500EF is Ropaque ™ TH500EF from Dow Chemicals hollow polymeric microspherepigment of approximate size 0.4 micron diameter, and 30% solids. TH1000is Ropaque ™ TH1000 from Dow Chemicals hollow polymeric microspherepigment of approximate size 1 micron diameter, and 26.5% solids Silver(Ag)-coated glass bubbles, available from CoSpheric LLC. Conductivesilver metal coated hollow glass microspheres 5-30 microns, density 0.75g/cm³, product ID: M-18-Ag-0.75

Kaolin clay coating 127-01 was coated onto 170 gsm (35 lbs/1000 sq ft)kraft laser & ink jet printer post cards, available from Juvo Plus IncIrwinsdale Calif., using a 5 Meyer rod and dried in a hot air oven at250° F. for 5 mins. Various coatings were selected and coated onto theboard, drying the coatings between each application. A representativearea was selected, and tested on the test rig illustrated in FIGS. 43A &43B. The distance to the lamp was set to 4.5″, 4500 grams of water wereweighed into the cooler, and the stirrer rotation was set to 600 rpm.The water temperature rise over 1 hour of lamp exposure was recorded.

Exp: Al foil none 1 clay 2 clay 3 clay BiOCl BiLite MgO Base: KraftKraft Kraft Kraft Kraft Kraft Kraft Kraft Coat 1 Al foil — 127-01 127-01127-01 127-01 127-01 127-01 Coat 2 — — — 127-01 127-01 TS110 137-02TS113 Coat 3 — — — — 127-01 — — — TempRise/° C. 1.3 4.1 3.7 3.5 3.5 3.43.1 3.5 W.m⁻² 87 274 247 234 234 227 207 234 Al foil: Aluminum foil(Reynolds heavy duty kitchen foil) was mounted dull-face down to Juvokraft paper using 3M spray adhesive.

TiO2 Exp: ZnO ZnS TiO₂ Al.ZnO AgGls* TH1000 TH500EF on Foil Base: KraftKraft Kraft Kraft Kraft Kraft Kraft Kraft Coat 1 127-01 127-01 127-01127-01 127-01 127-01 127-01 Foil Coat 2 TS111 TS112 137-06 127-02 136-01137-05 137-04 137-06 Coat 3 — — — — — — — — Temp 3.2 3.3 3.5 5.1 3.1 3.73.3 2.9 Rise/° C. W.m⁻² 214 221 234 341 207 247 221 194 *Ag-coated glassbubbles available from CoSpheric LLC. Conductive silver metal coatedhollow glass microspheres 5-30 microns, density 0.75 g/cm³, product ID:M-18-Ag-0.75

Exp: BiLite ZnO BiOCl ZnO/BiLite BiLite/ZnO Base: Kraft Kraft KraftKraft Kraft Coat 1 127-01 127-01 127-01 127-02 127-02 Coat 2 127-01127-01 127-01 TS111 137-02 Coat 3 137-02 TS111 TS110 137-02 TS111 TempRise/° C. 3.2 3.1 3.3 3 3.1 W.m⁻² 214 207 221 201 207

These data suggest that we can reduce the amount of energy absorbed by abox, or emitted from the inside surfaces of a box using coatings, byaround 30%. While aluminum foil, as well as aluminized bubble wrap arevery effective, they can cause problems if introduced into the repulpingstream, and in any case are challenging to recycle. Not only could manyof these coatings be applied to the interior and or exterior of the box,but could also be used as separate sheets of packaging, as illustratedas the loose sheets in FIG. 23A-23B.

Results of Emissivity Testing by Test Method #4:

Exp: Contrl 1 clay 2 clay 3 clay TiO₂ ZnS AgGls* ZnO Base: Kraft KraftKraft Kraft Kraft Kraft Kraft Kraft Coat 1 — 127-01 127-01 127-01 127-01127-01 127-01 127-01 Coat 2 — — 127-01 127-01 137-06 TS112 136-01 TS111Coat 3 — — — 127-01 — — — — ϵ @ 23° C. 0.900 0.859 0.883 0.885 0.8690.519 0.888 ϵ @ 30° C. 0.909 0.866 0.894 0.895 0.873 0.530 0.918 ϵ @ 40°C. 0.915 0.866 0.894 0.904 0.874 0.536 0.933 *Ag-coated glass bubbles,available from CoSpheric LLC. Conductive silver metal coated hollowglass microspheres 5-30 microns, density 0.75 g/cm³, product ID:M-18-Ag-0.75

Exp: BiLite BiLite ZnO BiOCl ZnO/BiLite BiLite/ZnO Base: Kraft KraftKraft Kraft Kraft Kraft Coat 1 127-01 127-01 127-01 127-01 127-02 127-02Coat 2 137-02 127-01 127-01 127-01 TS111 137-02 Coat 3 — 137-02 TS111TS110 137-02 TS111 ϵ @ 23° C. 0.856 0.873 0.885 0.861 0.848 0.868 ϵ @30° C. 0.873 0.875 0.897 0.876 0.860 0.877 ϵ @ 40° C. 0.882 0.871 0.9020.881 0.856 0.881Discussion of Emissivity vs. Heat Transfer Results

The inventors were surprised by the results of their own emissivitytests methods 1 and 2, as well as the emissivity results provided by theoutside laboratory (Thermal Emissivity Test Method #4). Several coatingshave been discovered by the inventors that apparently reduce thetransfer of radiant heat energy from an incandescent light bulb (as aproxy to the full-sun illumination of a delivered package) throughsheets of paper. The inventors were surprised to find that theemissivity results from the third party laboratory did not correlatewith the heat transfer through the materials measured by the coolerwindow tests. Clearly, the inventors may have discovered severalcoatings with non-obvious and unexpected thermal properties.

Thermal Conduction/ Sample Emissivity at 23° C. W · m⁻² Clay + ZnO +BiLite 0.848 201 Ag-coated glass 0.519 207 Clay + BiLite + ZnO 0.868 207Clay + Clay + ZnO 0.885 207 Clay + BiLite NT 207 Clay + Clay + BiLite0.861 214 Clay + ZnO 0.888 214 Clay + ZnS 0.869 221 Clay + Clay + BiOCl0.861 221 Clay + TiO₂ 0.885 234 Clay + Clay 0.883 234 Clay 0.859 237Kraft 0.900 274

Example 3. Sheets Containing Insulating Elements

Approximately 5.35 g portions of 35 lb liner board (International Paper)was shredded and repulped. Additional materials were added, along withsurfactants if necessary for wetting. While not yet optimumformulations, we had found that we could make paper sheets containinginsulating elements by adding surfactant, along with a cationicpolysaccharide, such as cationic Guar Gum, available from MakingCosmetics Inc., or a cationic starch sizing, or a synthetic retentionaid, such as Polymin P (BASE), also known as polyethylene imine), or ahigh molecular weight poly(acrylamide) available from various sources:Hydrophobically associating polymers may also be incorporated, such asN-alkyl poly(acrylamides.) We wished to understand the amount ofretained insulation in the paper following drying.

The following formulations were made up and cast as paper, dried at roomtemperature and then sent for ash content and moisture content analysis:

Formulation Target % % Moisture % Asb ID Materials Mass/g By mass paperPaper JL 24-02 Water 800.00  0% 8.4% 0.84% Control Pulp 5.35 JL 23-01Water 800.00 25% 6.2% 15.9% Pulp 5.35 Microspersion EZ 2.00 (neat)Perlite P-50 (20 1.78 micron) Cationic Guar 0.80 Gum JL 23-02 Water800.00 50% 7.2% 28.5% Pulp 5.35 Microspersion EZ 2.00 (neat) PerliteP-50 (20 5.35 micron) Cationic Guar 0.80 Gum JL 24-01 Water 800.00 50%6.7% 22.9% Pulp 5.35 Microspersion EZ 2.00 (neat) Perlite P-50 (20 5.35micron) Cationic Guar 2.00 Gum JL 25-02 800.00 25% 8.0% 8.8% Pulp 5.35Microspersion EZ 2.50 (neat) Perlite P-50 (20 1.78 micron) pH = 8-9Polymin P 0.80 JL 26-01 Water 800.00 50% 7.3% 16.8% Pulp 5.35Microspersion EZ 2.00 (neat) pH = 6.0 Perlite P-50 (20 5.35 micron) JL32-01 Water 800.00 25% 7.5% 14.7% Pulp 5.35 3M Glass Bubbles 1.78 0.5%a.q. Cationic 10.00 Guar Gum JL 32-02 Water 800.00 50% 6.8% 28.5% Pulp5.35 3M Glass Bubbles 5.35 iM30K 0.5% a.q. Cationic 10.00 Guar Gum

A mass balance was performed to confirm that a portion of the perliteand a portion of the finer was lost during the drawing and pressingprocess.

Repulpability Tests: Insulated Paper vs. Uline Insulated Cardboard Box

90 lb fiberboard was fed through a paper shredder. 5.35 g was weighedand pulped in hot water as usual. The pulp was more dense and moredifficult to disperse than the pulp from the 35 lb paper. Paper sheetswere made using the following formulations:

JL 41-01 water 800.00 Pulp - 90# shredded paper 12.50 iM30K glassbubbles 12.50 0.5% cationic guar gum 25.00 solution JL 41-02 water800.00 Pulp - 90# shredded paper 12.50 Microspersion EZ (neat) 1.60Perlite P-50 12.50 0.5% cationic guar gum 25.00 solution

As a control a 44-01), the existing method of shipping cold objects wasalso tested for repulpability. Corrugated cardboard from a BS121007single walled 12″×10″×17″ box sections were laminated to an insulatedbox liner, made from 3/16″ cool-shield bubble & metallized film,available from Uline as model number S-15223. The materials werelaminated using 3M aerosol spray adhesive.

Yield Yield based upon based upon Opera- total fiber original chargetional collected. to the pulper impact (% accepts) (% accepts) (Pass/Designation Summary Av. of 2 Av. of 2 Fail) 44-01 Control 64.7%  56.4%Fail 41-01 50% iM30K 98%  70% Pass 41-02 50% perlite P-50 93% 66.9% Pass

These data illustrate the validity that the approach of incorporatinginsulating elements into the paper structure has the potential toproduce a repulpable thermally insulating material for packaging.

Example 4. Additional Sheets Made for Moisture, Ash Content andRepulpability

35 lbs per 1000 sq. ft. single-ply sheets containing additives were madefor additional repulpability tests, consistent with the FiberboardAssociation voluntary standard for repulpability. Sheets FA, FD, FE, FF,FG were made using Grade 100 bleached pulp secondary fiber (supplied byDonco Recycling Solutions with offices in Chicago Ill.) The target basisweight for each sheet was 35 lbs per 1000 square feet (MSQ). Takingsample FD as an example, to make 35 MSQ board with 50% additive, 17.5lbs of dry pulp is mixed with 17.5 lbs of additive for every 1,000square feet of paper. Once ash content and moisture were measured, thesheets were then run through the repulping test in duplicate:

Sample Details, Moisture, and Ash Content:

Sample Details Test Results Measured Based upon Dried Material % %Moisture % % % additive ID Additive Additive Content Fiber Ash retentionFA (control) 0 8.4 98.7 1.4 N/A FD 20 μ spherical perlite 50 5.4 56.943.1 86.1 FE iM30k glass bubbles 50 5.1 54.5 45.5 90.9 FF Dicalite LD1006 50 5.0 52.6 47.4 94.7 FG 75 μ spherical perlite 50 6.2 62.1 37.975.7

Repulpability Test Data:

Total Repulped Total Repulped Initial Repulped mass mass Total IDCharge/g Mass/g accepted/g Rejected/g Fines/g FA 25.20 21.06 21.06 0.0004.14 FA 21.60 17.62 17.62 0.000 3.98 FD 25.20 14.21 13.87 0.251 11.08 FD25.10 14.81 14.80 0.008 10.29 FE 25.70 12.09 12.09 0.000 13.61 FE 25.4012.74 12.74 0.000 12.66 FF 25.10 14.64 14.64 0.004 10.46 FF 25.60 15.9815.24 0.036 10.32Repulpability Test Results Analysis—Taking Ash Content Into Account:

% Accepts % Accepts % accepts based on the Deposition based upon basedupon amount of fiber present on total fiber initial in the initialcharge equipment ID collected charge (additive ash excluded) noted: FA100.0 83.6 84.0 No FA 100.0 81.6 82.1 No FD 98.2 55.0 85.8 No FD 99.959.0 89.6 No FE 100.0 47.0 75.2 No FE 100.0 50.2 80.0 No FF 100.0 58.384.3 No FF 99.8 59.5 91.9 NoSurface Modification of Insulating Fillers:

Some fillers are quite hydrophobic, meaning that they are difficult towet out. Aerogels fall into this class, as do silicone-coatedmicro-spherical perlite, such as CenoStar P grades, from Cenostar Corp.Newbury MAor from American Stone Pioneers, Rolling Hills Estates, Calif.To wet these materials out, mid to low FMB surfactants are useful, suchas Microspersion EZ. Judicious selection of polymeric surfactants canalso be added to increase the negative surface charge of the wettedparticle. Such surfactants include Zetasperse 3800 (Evonik GmbH), whichis a comb co-polymeric anionic dispersant, and Disperbyk 190, availablefrom Byk, a division of Altana group. Even with surfactants, mechanicalhigh sheer mixing may be necessary to fully disperse these materials.High sheer mixing may be achieved using for instance a sawblade mixer,or a Silverson mixer. A regular kitchen blender may also be used to mixin short bursts of for instance 2-3 minutes, followed by a cooling timeto prevent the drive seals from overheating.

In formulations that contain surfactants, defoamers may also be neededto prevent troublesome foam build up. Defoamers are widely known, andmay be as simple as 1-octanol. They are usually low FMB surfactants,such as silicone containing surfactants, or surfactants such as Surfynol440, Surfynol 420, Surfynol 104e from Evonik GmbH, Particulatedispersions, such as hydrophobic silica dispersions may also be used asde-foamers.

Surface Modified Insulating Fillers

g JL 97-01 Water 125 Disperbyk 190 25 Microspersion EZ 0.134 Mix, thenadd with stirring: (add in Cenostar P-32 (75 micron 40.00 portions.)spherical perlite) JL 91-01 Water 143.1 Microspersion EZ 0.6 Disperbyk190 40.42 Mix and addi with stirring: Innova IC 3110 Aerogel 30.00 HighSheer Mix, wath Cooling 12 minutes. JL 60-01 Water 97.5 Zetasperse 31004 Surfynol 420 0.4 Microspersion EZ 0.4 Mix, then add with stirring:(add in Aerogel Innova IC 3110 20.00 portions.) High-sheer mix withcooling 15 mins.

Example 5. Paper Incorporating Thermal Insulation

The following formulations were made up and drawn into paper. Bleachedrecycled fiber, supplied by Donco Recycling Solutions. The pulp wasmeasured at 50% solids 50% moisture, and so 9 grams (9.05+/−0.05 g) wasweighed out in lieu of shredded fiber board.

Formulation ID Materials Mass/g JL 46-01 Water 800.00 CONTROL Pulp 4.5Microspersion EZ (neat) 1.60 (add last.) 0.5% a.q. Cationic Guar Gum10.00 JL 46-02 Water 800.00 Pulp 4.5 Microspersion EZ (neat) 1.60Perlite P-50 1.78 (add last.) 0.5% a.q. Cationic Guar Gum 10.00 JL 46-03Water 800.00 Pulp 4.5 Glass microbubbles (3M) 1.78 (add last.) 0.5% a.q.Cationic Guar Gum 10.00 JL 33-01 Water 800.00 Pulp 4.5 Perlite P-50 5.35Microspersion EZ (neat) 1.70 0.5% a.q. Cationic Guar Gum 10.00 JL 32-02Water 800.00 Pulp 4.5 3M Glass Bubbles iM30K 5.35 0.5% a.q. CationicGuar Gum 10.00 JL 49-01 Water 800.00 Pulp 4.5 Glass microbubbles (3M)10.70 Kroger Household Ammonia 4.00 (add last.) 0.5% a.q. Cationic GuarGum 10.00 JL 49-02 Water 800.00 Pulp 4.5 Perlite P-50 (20 micron) 10.70Microspersion EZ (neat) 1.60 Kroger Household Ammonia 4.00 (add last.)0.5% a.q. Cationic Guar Gum 10.00 JL 99-01 Water 800.00 Pulp 4.5 JL97-01 42.9 Mix, then add: 0.5% a.q. Cationic Guar Gum 10.00 JL 49-01Water 800.00 Pulp 4.5 Glass microbubbles (3M) 10.70 Kroger HouseholdAmmonia 4.00 (add last.) 0.5% a.q. Cationic Guar Gum 10.00 JL 49-02Water 800.00 Pulp 4.5 Perlite P-50 (20 micron) 10.70 Microspersion EZ(neat) 1.60 Kroger Household Ammonia 4.00 (add last.) 0.5% a.q. CationicGuar Gum 10.00 JL 70-01 Water 800.00 Pulp 4.5 Microspersion EZ 1.6Perlite P-35 75 micron 1.78 Household ammonia solution 2 Mix, then add:0.5% a.q. Cationic Guar Gum 10.00 JL 110-01 Water 800.00 Pulp 4.5Microspersion EZ 1.6 Perlite P-35 75 micron 4.5 Household Ammonia 4.00(add last.) 0.5% a.q. Cationic Guar Gum 10.00 JL 63-01 Water 800.00 Pulp4.5 JL 60-01 8.25 (add last.) 0.5% a.q. Cationic Guar Gum 10.00 JL 67-01Water 800.00 Pulp 4.5 JL 60-01 16.5 (add last.) 0.5% a.q. Cationic GuarGum 10.00Single Ply Samples:

Average Average Thickness/ TADT/ Formulation Explanation in ° C. JL46-01 Control 0.0092 22.7 JL 46-02 28.3% 20 micron perlite spheres0.0140 13.1 JL 46-03 28.3% Glass microbubbles (iM30K) 0.0149 12.2 JL33-01 54.3% 20 micron Perlite spheres 0.0226 6.9 JL 33-02 54.3% Glassmicrobubbles (iM30K) 0.0231 6.9 JL 49-01 70.4% Glass microbubbles(iM30K) 0.0257 5.4 JL 70-01 25% 75 micron perlite spheres 0.0177 9.1 JL110-01 50% 75 micron perlite spheres 0.0221 6.5 JL 99-01 66.7% 75 micronperlite spheres 0.0317 2.8 JL 63-01 25% Innova Aerogel 0.0179 8.2 JL67-01 50% Innova Aerogel 0.0254 4.3 JL 143-01 67% Innova Aerogel 0.03531.8 JL 68-01 25% Flaked Perlite 0.0169 9.7 (Dicalite LD 1006) JL 102-0150% Flaked Perlite 0.0178 7.4 (Dicalite LD 1006) JL 100-01 67% FlakedPerlite 0.0282 3.8 (Dicalite LD 1006) JL 126-01 71.4% Flaked Perlite0.0388 2.8 (Dicalite LD 1006) Thickness: This is the average over fivedisks with an average of three measurements for each disc of the paper(15 caliper measurements) Average TADT: This is the average for 5 sheetstested separately Thermal data TADT was adjusted to a thickness of 0.009inches for single ply sheets.

The inventors noted that the pulp treated as described readily floated,whereas untreated pulp tends to settle toward the bottom of a jar ofwater if left for 30 minutes. Without wishing to be bound by theory, theinventors speculate that they have hound the assumed negatively surfacecharged particles to the negatively surface charged fibers through theuse of a positively charged polymer (cationic guar gum). FIG. 44 shows aphotograph of two jars 310 of ˜2% solids pulp 11 in water 312. The lefthand jar 310 contains regular bleached secondary pre-consumer fiber 11,while the jar 310 on the right contains similar pulp 11 combined withaerogel 12 in a similar formulation to JL 67-01.

Clearly, the Average Thickness Adjusted Delta-T (see, FIG. 46) showsthat inclusion of the insulating filler 12 was slowing down heattransfer through the paper sheet 10. These, along with some additionaldata are shown in FIG. 46 as a bar chart. Note that the thickness of thesheet 10 was taken into account according to the formula provided in thetest method described previously. From these data, we realized that thelarger insulating particles 75 micron perlite spheres seemed to be moreeffective than the smaller 20 micron perlite spheres.

As much of the pulp 11 floated, the inventors realized that gravitationmay be classifying the insulating particles 12. FIG. 45 contains a setof scanning electron micrographs (SEMs) which compare the wire side tothe felt side of the cooched paper sheet 10. The SEMs clearly show thatin the case of 20 micron & 75 micron perlite microspheres 12, andaerogel 12, the felt side (also the upper side during paper formingusing our lab equipment) is more populated with insulating particles 12than the wire side, evidencing an uneven distribution of insulatingparticles 12.

Double Ply Samples:

The inventors hypothesized that the uneven distribution of insulatingparticles 12 within paper sheets 10 may be helping provide insulation.The following experiment was designed to investigate the thermalinsulative effect of having all of the insulation in one of two layers10 vs. more evenly distributed through two layers 10.

DP2 DP3 5% perlite 10% perlite DP1 (20 micron (20 micron grams No fillerhollow spheres) hollow spheres) Water/g 800 800 800 Pulp/g 4.5 4.5 4.5Surfactant/g — 1.6 1.6 Perlite (20 — 0.25 0.50 micron)/g Mix Mix Mix0.5% Cationic 10 10 10 Guar Gum. aq/g Surfactant = Microspersion EZSeveral sheets were made from these pulp formulations, dried, tested,and thermally analyzed.

Sheet: 1^(st) ply 2^(nd) ply Thickness/in TADT/° C. DL1 (control) DP1DP1 0.0177 9.6 DL2 DP2 (5% P) DP2 (5% P) 0.0158 8.2 DL3 DP3 (10% P) DP10.0190 7.2

Clearly, these data demonstrate the advantage of a non-uniformdistribution of insulating particles 12 within the cross section of thepaper sheet 10.

FIG. 47 depicts SEMs of sheets DL2 (MVA Sample 12905AD1703) and DL3 (MVASample 12905AD1702), both surfaces of the sheets as well as crosssections. The felt side of DL3 shows slight surface contamination(probably from perlite adhering to the felt) however, a clean crosssection. DL2 cross section shows perlite spheres distributed throughoutthe paper thickness over the two plies.

Three Ply Sheets:

Sheets with three plies were conceived in which the two outer sheets arepulp and the inner layer of the sandwich contains a high concentrationof insulating materials. A flaked grade of perlite was also included inthese experiments, Dicapearl LD1006 supplied by Dicalite ManagementGroup. This material was mixed into pulp without the addition of otherassistants. After mixing.

TP2 TP5 TP6 50% perlite TP3 TP4 66.7%: 50 um 66.7% (75 micron 50% 66.7%flaked iM30K DP1 hollow flaked flaked 50% 20 u glass No filler spheres)perlite perlite spherical bubbles Water/g 800 800 800 800 800 800 Pulp/g4.5 4.5 4.5 4.5 4.5 4.5 Surfactant/g 1.6 1.6 Perlite (75 4.5 micron)/gPerlite (20 4.5 micron)/g Dicapearl 4.5 9.0 4.5 LD1006 iM30K 9.0Household 2-4 2-4 2-4 ammonia/g Mix Mix Mix Mix Mix Mix 0.5% Cationic 1010 10 10 10 10 Guar Gum aq/gResults Thickness Adjusted Temperature Change (Delta-T)—adjusting for athickness of 0.045 inches caliper.

Sheet: 1^(st) ply 2^(nd) ply 3^(rd) ply Thickness/in TADT*/° C. TL1(control) DP1 DP1 DP1 0.0228 28.8 TL2 DP1 TP2 (50% 75 u Perlite) DP10.0415 13.4 TL3 DP1 TP3 (50% flaked) DP1 0.0398 14 TL4 DP1 TP4 (66.7%flaked) DP1 0.0535 8.3 TL5 DP1 TP5 combination DP1 0.0527 8.6 TL6 DP1TP6 (66.7% glass bubbles) DP1 NT NT *Thickness adjusted to 0.045 inchescaliper.Results Thickness Adjusted Temperature Change (Delta-T)—adjusting for athickness of 0.009 inches caliper allows comparison to single plysamples.

Sheet: 1^(st) ply 2^(nd) ply 3^(rd) ply Thickness/in TADT**/° C. TL1(control) DP1 DP1 DP1 0.0228 5.8 TL2 DP1 TP2 (50% 75 u Perlite) DP10.0415 2.7 TL3 DP1 TP3 (50% flaked) DP1 0.0398 2.8 TLA DP1 TP4 (66.7%flaked) DP1 0.0535 1.7 TL5 DP1 TP5 combination DP1 0.0527 1.7**Thickness adjusted to 0.009 inches caliper.

These data show that we are able to incorporate low density insulatingmaterials into a paper structure to increase the thermal insulativeproperties by a factor of at least 3-4.

Sheets TL1 through TL5 contain a mixture of pulp and additive in the2^(nd) (middle) ply. It is also possible to make insulating paper bycreating a 2^(nd) ply (middle layer) that does not contain pulp. Asshown in FIG. 12, insulating filler or additive (12) may be added aseither a concentrate or a dry powder between two plies of fiber (10).Similarly, a concentrated slurry of insulating; additive may beincorporated between two plies using a slot-die coater, or a spray boomas shown in FIG. 13E. If the application head is close enough to thebottom layer headbox on the forming line, then the amount of water willbe high enough that some mixing of the two layers may be expected. Inthis regard, fibers may help with z-directional adhesion between thethree layers in the finished paper, while maintaining a non-uniformcross sectional sheet.

The middle layer could comprise a concentrate such as formulation JL97-01. The middle layer may optionally include a binder, such as a latexRovene 6400, or poly(vinyl acetate), or a modified starch, or a mixtureof cooked and uncooked starch, or a water soluble synthetic polymer suchas poly(vinyl alcohol). If necessary, a defoamer may be added to controlfoam. Surface active agents may also be included in the middle layerslurry to help wet-out and stabilize the insulating elements, such asDisperbyk 190, Zetasperse 3100, Surfynol 440, or numerous other resinousand non-resinous surfactants.

The bottom and top plies may contain a retention aid, a flocculant, or abinder. Such materials may be cationic, such as poly(ethylene imine),poly(acrylamide), or quaternary ammonium functionalized naturalpolymers, such as cationic guar gum. In this way, migration of theadditive as water drains from the top ply through the underlying middleand bottom ply is limited and fines are trapped.

Concentrates for 2^(nd) Ply (Middle Layer):

Mass/g Formula JL 97-01: 75 u spherical perlite concentrate Water 125Microspersion EZ 0.134 Disperbyk 190 25.0 Mix, then add in portionswhile mixing: Cenostar P-32 (75 micron spherical perlite) 40.0 FormulaJL 147-01: glass bubbles concentrate Water 80 Rovene 4100 (binder of~50% solids) 20 iM30K glass bubbles (3M) 90 Formula glass bubblesconcentrate, binder free Water 85 iM30K glass bubbles (3M) 90

These coatings may be applied to the paper forming line shortly after alayer of pulp exits the headbox. The concentrate coatings may be appliedusing a spray nozzle, or a blade coater, or a curtain coater, or aslot-die coater. A coagulant or flocculant may be then be applied on topof the middle ply via spraying, or slot-die coating as non-limitingexamples. The coagulant flocculant may also be incorporated inadditional layers of pulp below and above the middle insulating layer.

It stands to reason that while a three-ply system has been explored,many more plies may be similarly formed, resulting in 5 ply, 7 ply, orhigher-ply systems via similar processes. FIG. 13G depicts a four-plypaper machine.

Example 6. Corrugated Samples of 3-ply Paper Sheets

An antique desk-top hand cranked corrugator was purchased. Thecorrugator indicated U.S. Reexam Pat. No. RE009,127 “Fluting-Machine”,re-issued Mar. 23, 1880 to H. Albrecht.

A sheet of TL1 was hung from inside an inverted 5 gallon pail and heldover a boiling tea kettle to steam the sheet. The cast iron hand-crankedcorrugator was warmed with a hair dryer, and the warm steamed sheet waspromptly rippled. This was promptly bonded between two non-corrugatedsheets of TL1 to make a rudimentary corrugated structure.

Single ply filled sheets were hand pressed in the lab and dried:

Sheet Composition ID EJ EK Water/g 800 800 Pulp/g 4.5 4.5 Flaked PerliteLD1006/g 9.0 iM30K glass bubbles/g 9.0 Household ammonia/g 2-4

A sheet of TL1 was hung from inside an inverted 5 gallon pail and heldover a boiling tea kettle to steam the sheet. The cast iron hand-crankedcorrugator was warmed with a hair dryer, and the warm steamed sheet waspromptly fluted. This was promptly bonded between two non-corrugatedsheets of EJ to make a rudimentary corrugated structure. This procedurewas repeated using EK sheets for all three layers.

A sheet of TL1, EJ, and EK were each coated with Kaolin clay formulation127-01, then dried, and then coated with 137-02 (BiLite (BASF)—bismuthoxychloride coated mica flakes) and dried. More uncoated sheets weresteamed and fluted, and similar corrugated structures were producedincorporating one of the coated sheets with the coating side facing outas depicted in FIG. 48.

10 cm diameter disks were cut of each sample, and mounted into a coolerwindow for thermal testing. Prior to sealing with marine adhesive, thesamples were gently pushed into the front of the cooler window so thatthe face of the composite was flush with the front of the cooler. 10 cmdiscs of the following were also cut as controls: Aluminized bubblewrap, corrugated C-flute (35 lbs·MSQ kraft liners with 23 lb medium,Corrugated Supplies Inc.), corrugated B-flute (35 lbs·MSQ kraft linerswith 23 lb medium, Corrugated Supplies Inc.), triple wall corrugated B-Cflute (35 lbs·MSQ kraft liners with 23 lb medium, Corrugated SuppliesInc.).

Because these samples had significant thickness, temperature rise wasmonitored over a an initial period of time until three consecutive 15minute temperature readings showed an increase in temperature within+/−0.1° C. of each other. Upon attaining consistent temperature increasereadings over 15 minutes, this was designated as pseudo-steady state.The temperature of the outside lamp-facing surface was also measuredusing a hand-held pyrometric infra-red thermometer, taking care to trynot to allow reflections of the hot lamp from interfering. Usually, apseudo-steady state situation of incremental temperature increases wasestablished within 15 minutes of run time.

Results of Controls

corrugate corrugate Corrugate Bubblewrap Paper C-Flute B-Flute BC FluteAluminized Ave. Thickness/mm 4 3.175 6.35 3.175 Coating 1 — — — —Coating 2 — — — — (lamp facing) 1 hr Water 3.04 3.2 2.8 1.4 T Rise/° C.Ave temp difference 96.4 91.1 133.8 Very noisy outer face of data.window vs. 74 +/− 25° C. water/° C. W · m⁻² 203 214 187 94

corrugate corrugate corrugate corrugate corrugate corrugate ControlFlake Perl. Gls Bubls Coated Flk Perl Gls Bubls Paper TL1 EJ EK TL1 EJEK Av. Thkns/mm 3.87 5.51 5.68 4.11 5.44 6.36 Coating 1 — — — 127-01127-01 127-01 Coat. 2 lamp — — — 137-02 137-02 137-02 1 hr T Rise/° C.2.4 2.13 NT* 2 1.73 1.8 Av. Delta T outer 78.5 87.1 NT* 74.2 86.2 77.5face of window vs. water/° C. W.m⁻² 154 143 134 116 120 * Structurefailed during testing-delaminated.

These data demonstrate the additive combination of addressing bothradiative heat transfer as well as conductive heat transfer.

Example 7. Coffee Cup Insulated Sleeve Demonstration

FIG. 48 depicts a single faced beverage cup insulated sleeve 320,commonly used to prevent painful burning of coffeeshop patrons orderinghot coffee in a ‘to go’ disposable cup (see, cup in FIG. 49). The device320 consists of a single-faced corrugated kraft fiberboard 100″ cut intoa specific shape to form a truncated conical structure 320 that slidesover the hot beverage cup (see again, cup in FIG. 49), protecting theholder from heat transmitted through the thin walled PE-lined paper cup.While the present invention is directed at devices 60/62 to maintainfoods and other perishables at low temperature, transmission of heatfrom hot liquids affords a cognitively intuitive demonstration of theinsulating technology. In this regard, additional sheets of TL4 wereproduced. One sheet of TL4 was steamed for 5 minutes in an inverted 5gallon pail and promptly corrugated using the pre-warmed cast ironantique hand-cranked tabletop corrugator. This corrugated TL4 sheet wasplaced onto a flat sheet of TL4 that had been sprayed with 3M contactadhesive to form a single faced corrugate 110″. A commercially availablehot beverage cup sleeve was deconstructed to determine the net shape.The net shape 321 was cut from the TL4 single faced corrugate 110″. Theresultant device 320 was weighed, and found to weigh 10 g.

Juvo kraft board 35 lbs/1,000 sq ft (170 gsm) postcards were alsocorrugated. 3 flat sheets were laminated and then one corrugated sheetwas attached to the composite. When this net was cut out and formed intoa sleeve, it also had a mass of 10 g. This composite device wasdesignated “control” as it did not include insulating materials.

Both the Juvo kraft control, the TL4 test device, were placed over two“tall” sized PE-lined paper cups 360 obtained from a Starbucks® store.In addition, an expanded polystyrene) cup 360 was also placed close byfor comparison. A kettle of water was boiled. As quickly as safelypossible, all three cups 360 were filled with boiling water, and a timerstarted. Every 30 seconds from filling, an infra-red pyrometerthermometer was used to measure the temperature of the outside of thetwo sleeves made, as well as the apparent temperature of the EPS cup.

Time from filling/s Expanded PS Control (kraft) TL4 30 61.0° C. 54.2° C.48.7° C. 60 63.0° C. 57.3° C. 53.3° C. 120 60.2° C. 57.6° C. 52.5° C.180 58.8° C. 58.6° C. 54.3° C. 240 56.7° C. 58.2° C. 55.0° C. 300 55.6°C. 55.0° C. 51.4° C.

As can be clearly seen, the external temperature of the TL4 sleeve 320was consistently lower in temperature than both the control sleeve andthe expanded poly(styrene) cup 360.

The present invention is described above and further illustrated belowby way of claims, which are not to be construed in any way as imposinglimitations upon the scope of the invention. On the contrary, it is tobe clearly understood that resort may be had to various otherembodiments, modifications, and equivalents thereof which, after readingthe description herein, may suggest themselves to those skilled in theart without departing from the spirit of the present invention and/orthe scope of the appended claims.

What is claimed is:
 1. An insulated paper product comprising: two ormore paper layers and insulating material, said insulating materialcomprising particles having an average particle size of less than about1000 microns (μm), said particles comprising perlite, expanded perlite,perlite hollow microspheres, perlite microspheres, milled expandedperlite, perlite flakes, cenospheres, glass bubbles, glass microbubbles,vermiculite, hollow expanded vermiculite, or any combination thereof,the two or more paper layers being bonded to one another so as to forman integral paper product, wherein the integral paper product (i) has anon-uniform distribution of the insulating material therethrough and(ii) is repulpable, and wherein the insulating material has a materialbulk density of less than 0.6 gram per cubic centimeter (g/cm³).
 2. Theinsulated paper product of claim 1, wherein said insulated paper productcomprises at least one layer in combination with said two or more paperlayers with said at least one layer comprising said insulating material.3. The insulated paper product of claim 1, wherein one or more paperlayers within said two or more paper layers comprise the insulatingmaterial.
 4. The insulated paper product of claim 1, wherein theintegral paper product comprises from two to 24 paper layers.
 5. Theinsulated paper product of claim 1, wherein the insulated paper productfurther comprises one or more non-paper layers.
 6. The insulated paperproduct of claim 5, wherein the one or more non-paper layers comprise agypsum layer, a clay-containing layer, a polymer coating, apigment-containing layer, a fabric layer, a layer of insulatingmaterial, a metal film layer, a foam layer, or any combination thereof.7. The insulated paper product of claim 5, wherein the one or morenon-paper layers comprise a coating that provides a lower emissivity ofthe insulated paper product.
 8. The insulated paper product of claim 5,wherein the one or more non-paper layers comprises bismuth oxychloride,mica, bismuth oxychloride-coated mica, zinc oxide, zinc sulfide, cadmiumsulfide, bismuth vanadate, gypsum, sericite, powdered silicon,silver-coated glass bubbles, aluminum oxide, or any mixture orcombination thereof.
 9. The insulated paper product of claim 5, whereinthe one or more non-paper layers comprises bismuth oxychloride, mica,zinc oxide, sericite, gypsum, aluminum oxide, or any mixture orcombination thereof.
 10. The insulated paper product of claim 1, whereinthe insulating material comprises particles having an average particlesize of less than about 500 microns (μm).
 11. The insulated paperproduct of claim 1, wherein the insulating material comprises particleshaving a multi-modal particle size distribution.
 12. The insulated paperproduct of claim 1, wherein each paper layer that contains insulatingmaterial comprises from 15.0 weight percent (wt %) to 80.0 wt % fibers,and from about 85.0 wt % to about 20.0 wt % of the insulating material,based on a total weight of a given paper layer within the two or morepaper layers.
 13. The insulated paper product of claim 1, wherein theinsulated paper product is molded to form a three-dimensional object.14. The insulated paper product of claim 1, wherein said insulated paperproduct comprises a storage container, said storage container comprisinga storage volume at least partially surrounded by one or more containerwalls, each of the one or more container walls comprising the two ormore paper layers and the insulating material.
 15. The insulated paperproduct of claim 14, wherein the storage volume is completely surroundedby or surroundable by the one or more container walls.
 16. The insulatedpaper product of claim 14, wherein the one or more container wallsfurther comprise a gypsum layer, a clay-containing layer, a polymercoating, a pigment-containing layer, a bismuth oxychloride-containinglayer, a mica containing layer, an aerogel containing layer, a fabriclayer, a layer of insulating material, a metal film layer, a foam layer,a layer of air, a coating that lowers an emissivity of the one or morecontainer walls, a coating that lowers a thermal conductivity of the oneor more container walls, a coating that enhances a water-repellency ofthe one or more container walls and comprises a wax, or a fluorocarbon,or an epoxy or a urethane, or a silicone-based coating, or a polymericemulsion or latex, or any combination thereof.
 17. The insulated paperproduct of claim 14, wherein the storage container comprises a box. 18.The insulated paper product of claim 14, wherein the storage containercomprises a cup, a mug, a flask, a thermos, a clam shell type boxpackaging for hot food, a salad container for chilled food, a paddedenvelope, or a shipping container.
 19. The insulated paper product ofclaim 14, further comprising a coating on (i) an inner surface, (ii) anouter surface, or (iii) both (i) and (ii) of the storage container, thecoating comprising materials selected from mica, bismuth oxychloride,bismuth oxychloride-coated mica, sericite, gypsum, aluminum oxide, orany combination thereof.
 20. A method of using the insulated paperproduct of claim 14, said method comprising: positioning an objectwithin the storage volume of the storage container.
 21. The insulatedpaper product of claim 1, wherein each of the two or more paper layerscomprises one or more additives, other than the insulating material,said one or more additives comprising copper ions, waxes, syntheticfibers, silica, surface modified silica, transition metal surfacemodified silica, cyclodextrin, sodium bicarbonate, silicones to impartgrease and water resistance, metalized ceramic particles, metalizedfibers, cationic starches, cationic polymers, fillers, sizes, binders,clay, bentonite clay, kaolin clay, calcium carbonate, calcium sulfate, aflocculant, a retention aid, or any combination thereof.
 22. Theinsulated paper product of claim 1, wherein at least one layer of saidinsulated paper product comprises starch.
 23. An insulated paper productcomprising: two or more paper layers and insulating material, saidinsulating material comprising particles having an average particle sizeof less than about 1000 microns (μm), said particles comprising perlite,expanded perlite, perlite hollow microspheres, perlite microspheres,milled expanded perlite, perlite flakes, cenospheres, glass bubbles,glass microbubbles, vermiculite, hollow expanded vermiculite, or anycombination thereof, the two or more paper layers being bonded to oneanother so as to form an integral paper product, wherein the integralpaper product (i) has a non-uniform distribution of the insulatingmaterial therethrough and (ii) is repulpable, and wherein thenon-uniform distribution of insulating material within said integralpaper product comprises (i) at least two paper layers with theinsulating material therein and (ii) at least one paper layersubstantially free of the insulating material.
 24. The insulated paperproduct of claim 23, wherein the integral paper product comprises fromtwo to 24 paper layers.
 25. An insulated paper product comprising: twoor more paper layers and insulating material, said insulating materialcomprising particles having an average particle size of less than about1000 microns (μm), said particles comprising perlite, expanded perlite,perlite hollow microspheres, perlite microspheres, milled expandedperlite, perlite flakes, cenospheres, glass bubbles, glass microbubbles,vermiculite, hollow expanded vermiculite, or any combination thereof,the two or more paper layers being bonded to one another so as to forman integral paper product, wherein the integral paper product (i) has anon-uniform distribution of the insulating material therethrough and(ii) is repulpable, and wherein all paper layers within said integralpaper product comprise the insulating material.
 26. The insulated paperproduct of claim 25, wherein the integral paper product comprises fromtwo to 24 paper layers.
 27. An insulated paper product comprising: twoor more paper layers and insulating material, said insulating materialcomprising particles having an average particle size of less than about1000 microns (μm), said particles comprising perlite, expanded perlite,perlite hollow microspheres, perlite microspheres, milled expandedperlite, perlite flakes, cenospheres, glass bubbles, glass microbubbles,vermiculite, hollow expanded vermiculite, or any combination thereof,the two or more paper layers being bonded to one another so as to forman integral paper product, wherein the integral paper product (i) has anon-uniform distribution of the insulating material therethrough and(ii) is repulpable, wherein the integral paper product comprises (i) afirst linerboard layer comprising one or more first paper layers, (ii) asecond linerboard layer comprising one or more second paper layers, and(iii) a fluted paper layer comprising one or more fluted paper layerspositioned between the first linerboard layer and the second linerboardlayer, and one or more of (i) said first linerboard layer, (ii) saidsecond linerboard layer, and (iii) said fluted paper layer independentlycomprises insulating material therein or thereon, and wherein saidfluted paper layer provides pockets of air between said first linerboardlayer and said second linerboard layer, and said pockets of airrepresent from about 20 to 80 volume percent of a total volume occupiedby said fluted paper layer.
 28. The insulated paper product of claim 27,further comprising an adhesive that bonds portions of said fluted paperlayer to portions of said first linerboard layer and said secondlinerboard layer.
 29. The insulated paper product of claim 28, whereinsaid adhesive has the insulating material dispersed therein.
 30. Aninsulated paper product comprising: two or more paper layers andinsulating material, said insulating material comprising particleshaving an average particle size of less than about 1000 microns (μm),said particles comprising perlite, expanded perlite, perlite hollowmicrospheres, perlite microspheres, milled expanded perlite, perliteflakes, cenospheres, glass bubbles, glass microbubbles, vermiculite,hollow expanded vermiculite, or any combination thereof, the two or morepaper layers being bonded to one another so as to form an integral paperproduct, wherein the integral paper product (i) has a non-uniformdistribution of the insulating material therethrough and (ii) isrepulpable, and wherein at least one layer of said two or more paperlayers has a layer density of less than 1.0 g/cm³.
 31. An insulatedpaper product comprising: two or more paper layers and insulatingmaterial, said insulating material comprising particles having anaverage particle size of less than about 1000 microns (μm), saidparticles comprising perlite, expanded perlite, perlite hollowmicrospheres, perlite microspheres, milled expanded perlite, perliteflakes, cenospheres, glass bubbles, glass microbubbles, vermiculite,hollow expanded vermiculite, or any combination thereof, the two or morepaper layers being bonded to one another so as to form an integral paperproduct, wherein the integral paper product (i) has a non-uniformdistribution of the insulating material therethrough and (ii) isrepulpable, and wherein said integral paper product has an integralpaper product density of less than 1.0 g/cm³.
 32. An insulated paperproduct comprising: two or more paper layers and insulating material,said insulating material comprising particles having an average particlesize of less than about 1000 microns (μm), said particles comprisingperlite, expanded perlite, perlite hollow microspheres, perlitemicrospheres, milled expanded perlite, perlite flakes, cenospheres,glass bubbles, glass microbubbles, vermiculite, hollow expandedvermiculite, or any combination thereof, the two or more paper layersbeing bonded to one another so as to form an integral paper product,wherein the integral paper product (i) has a non-uniform distribution ofthe insulating material therethrough and (ii) is repulpable, and whereinsaid insulated paper product comprises a storage container, said storagecontainer comprising a storage volume at least partially surrounded byone or more container walls, each of the one or more container wallscomprising the two or more paper layers and the insulating material, andsaid insulated paper product further comprises a coating on (i) an innersurface, (ii) an outer surface, or (iii) both (i) and (ii) of thestorage container, the coating having a thermal emissivity of less than0.90 at 23° C., as measured using Thermal Emissivity Method #4.
 33. Theinsulated paper product of claim 32, wherein the storage containercomprises a cup, a mug, a flask, a thermos, a clam shell type boxpackaging for hot food, a salad container for chilled food, a paddedenvelope, or a shipping container.
 34. A method of using the insulatedpaper product of claim 32, said method comprising: positioning an objectwithin the storage volume of the storage container.